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FIELD OF THE INVENTION
The present invention relates generally to medical methods and devices, and more particularly to an improved method for folding a balloon which is utilized to radially expand an intraluminal prosthetic device such as a stent or stented graft.
BACKGROUND OF THE INVENTION
In modern medical practice, various types of radially expandable endoluminal devices, such as stents and stented grafts, are frequently implanted within the lumens of blood vessels or other anatomical conduits. Typically, these endoluminal devices are initially mounted on a pliable delivery catheter while in a radially compact state, and the delivery catheter (having the radially compact endoluminal device mounted thereon) is then transluminally advanced through the vasculature or other system of anatomical passageway(s), to the location where the endoluminal device is to be implanted. Thereafter, the endoluminal device is caused to radially expand to an operative, radially expanded configuration wherein it engages the surrounding wall of the blood vessel or other anatomical conduit, frictionally holding the endoluminal device in its desired position within the body.
Many of the radially expandable endoluminal devices of the prior art have been generally classifiable in one of two (2) categories: i.e., self-expanding or pressure-expandable. Endoluminal devices of the "self-expanding" variety are usually formed of a resilient material (e.g., spring metal) or shape memory alloy, which automatically expands from a radially collapsed configuration to a radially expanded configuration, and are typically mounted on a delivery catheter which incorporates some constraining apparatus (e.g., a retractable restraining member, sheath or wall of the delivery catheter) which operates to hold the device in its radially compact state until it is desired to release the device at its site of implantation.
Endoluminal devices of the "pressure-expandable" variety are typically formed at least partially of malleable or plastically deformable material which will deform as it radially expands, and are initially formed in a radially compact configuration and mounted on a delivery catheter which incorporates a balloon or other pressure-exerting apparatus which serves to pressure-expand the endoluminal device when at its desired implantation site. Typically, when these pressure-expandable endoluminal devices are mounted on a balloon catheter, the balloon is initially deflated and furled, twisted or twined to a small diameter, to allow the radially compact endoluminal device to be mounted thereon. Subsequent inflation of the balloon will then cause the endoluminal device to radially expand, to its radially expanded, operative diameter.
In some procedures, it is important that the endoluminal device be prevented from rotating or undergoing torsional deformation as it is being expanded from its radially compact configuration, to its radially expanded configuration. Such prevention of rotation or torsional deformation is particularly important when precise rotational orientation of the endoluminal device must be maintained.
One example of a procedure wherein precise rotational orientation of an endoluminal device is critical, is the deployment of a modular endoluminal graft within a bifurcated or branched segment of a blood vessel (e.g., within the aorto-iliac bifurcation to treat an infrarenal aortic aneurysm which involves the iliac arteries). In such procedures, a primary graft is initially implanted within one of the involved blood vessels (e.g., within the infrarenal aorta), such than one or more opening(s) formed in the primary graft is/are aligned with the other involved vessel(s) (e.g.,with one or both of the iliac arteries). One or more secondary graft(s) is/are then implanted within the other involved blood vessel(s) (one or both of the iliac arteries) and such secondary graft(s) is/are connected to the corresponding opening(s) formed in the primary graft. Thus, in these "modular" endovascular grafting procedures, it is important that the primary graft be positioned and maintained in a precise, predetermined rotational orientation to ensure that the opening(s) of the primary graft will be properly aligned with the other involved blood vessel(s). Any untoward rotation or torsional deformation of the primary graft during its radial expansion may result in nonalignment of the primary graft's opening(s) with the other involved vessel(s), and could render it difficult or impossible to subsequently connect the secondary graft(s) to the opening(s) in the primary graft, as desired.
Examples of modular endovascular grafts useable for aorto-iliac implantation as summarized above include those described in the following United States patents: U.S. Pat. No. 4,577,631 (Kreamer); U.S. Pat. No. 5,211,658 (Clouse); U.S. Pat. No. 5,219,355 (Parodi et al.); U.S. Pat. No. 5,316,023 (Palmaz et al.); U.S. Pat. No. 5,360,443 (Barone et al.); U.S. Pat. No. 5,425,765 (Tifenbrun et al.); U.S. Pat. No. 5,609,625; (Piplani et al.); U.S. Pat. No. 5,591,229 (Parodi et al.); U.S. Pat. No. 5,578,071 (Parodi); U.S. Pat. No. 5,571,173 (Parodi); U.S. Pat. No. 5,562,728 (Lazarus et al.); U.S. Pat. No. 5,562,726 (Chuter); U.S. Pat. No. 5,562,724 (Vorwerk et al.); U.S. Pat. No. 5,522,880 (Barone et al.); and U.S. Pat. No. 5,507,769 (Marin et al.).
In cases where a pressure-expandable endoluminal device is mounted upon and expanded by a balloon catheter (as described above), any significant rotation or torsional motion of the balloon during inflation, may result in corresponding rotation and/or torsion of the endoluminal device. This is especially true in cases where the balloon is relatively bulky, or of relatively large diameter, such as those balloons used to expand and implant endoluminal devices in large diameter vessels, such as the human aorta. Thus, the usual technique of furling, twining or twisting the deflated balloon prior to mounting of the endoluminal device thereon, may result in untoward rotation of torsional deformation of the expanding endoluminal device as the balloon is inflated.
Accordingly, there exists a need in the art for the development of new methods and/or devices for preventing rotation or torsional deformation of radially expandable endoluminal devices (e.g., stents, stented grafts, etc.) during implantation.
SUMMARY OF THE INVENTION
The present invention provides a method for forming countervailing folds in a deflated, catheter-mounted balloon to deter subsequent rotational movement or torsional deformation of a radially expandable endoluminal device which has been mounted upon the deflated balloon, and is expanded by inflation of the balloon.
In accordance with the method of the present invention, there is provided a balloon folding method which basically comprises the steps of:
a. forming a plurality of longitudinal furrows in the balloon, said longitudinal furrows defining balloon portions therebetween; and,
b. folding each balloon portion a first time, in a first direction, to thereby form singly-over-folded balloon portions;
c. folding each balloon portion a second time, in a second direction, to thereby form doubly-over-folded balloon portions.
After completion of step c, the doubly-over-folded balloon portions may optionally be overlapped with one another. Also, a compressive outer jacket (e.g., a tape wrap or a tubular sleeve) may optionally be applied to compress or flatten the folded balloon prior to mounting of the radially expandable endoluminal device on the balloon.
Further in accordance with the invention, there is provided a system for implanting a radially expandable endoluminal device within a luminal anatomical structure (e.g., a blood vessel). The system generally comprises a) a catheter having a deflated balloon mounted thereon and b) an endoluminal device mounted on said deflated balloon in a radially compact state, said device being radially expandable to an expanded state upon inflation of said balloon. The catheter balloon is folded in accordance with the above-summarized balloon folding method of the present invention. The endoluminal device mounted on the balloon may be any suitable type of radially expandable device, including but not necessarily limited to stents, grafts, stented grafts, and other radially expandable intraluminal apparatus.
Further objects and advantages of the present invention will become apparent to those skilled in the relevant art upon reading and understanding the following detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1a is a partial elevational view of the distal portion of a delivery catheter having a foldable balloon of the present invention mounted thereon in its deflated state.
FIG. 1b is an elevational view of a portion of a delivery catheter having a balloon of the present invention, in its inflated state.
FIG. 2a is a cross-sectional view through line 2a--2a of FIG. 1b.
FIG. 2b is a cross-sectional view through line 2a--2a of FIG. 1b, showing a first step in folding of the balloon in accordance with the present invention.
FIG. 2c is a cross-sectional view through line 2a--2a of FIG. 1b showing a second step in the folding of the balloon in accordance with the present invention.
FIG. 2d is a cross-sectional view through line 2a--2a of FIG. 1b showing a third step in the folding of the balloon in accordance with the present invention.
FIG. 2e is a cross-sectional view through line 2a--2a of FIG. 1b showing a fourth step in the folding of the balloon in accordance with the present invention.
FIG. 2f is a cross-sectional view through line 2a--2a of FIG. 1b showing the final step in the folding of the balloon in accordance with the present invention.
FIG. 2g is a cross-sectional view through line 2a--2a of FIG. 1b showing the folded balloon of FIG. 2f after a pressure-exerting rapping has been applied thereto, in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The following detailed description and the accompanying drawings to which it refers are provided for the purpose of describing presently preferred embodiments and/or examples of the invention only, and are not intended to limit the scope of the invention in any way.
FIGS. 1a and 1b show a balloon catheter of the present invention, comprising an elongate pliable catheter body 10 which has a balloon 12 mounted thereon. A balloon inflation lumen (not shown) extends through the catheter body to permit inflation fluid to be passed into, and withdrawn from, the balloon 12. FIG. 1a shows the balloon 12 in a collapsed state after having been folded in accordance with the present invention, while FIG. 1b shows the same balloon 12 in its fully inflated state.
As best appreciated from the showing of FIG. 1b, the balloon preferably comprises a generally cylindrical side wall 14, a tapered proximal end wall 16a, a portion of which is fused to the catheter body 10 at the proximal end of the balloon 12, and a tapered distal end wall 16b, a portion of which is fused to the catheter body 10 at the distal end of the balloon 12. The balloon 12 may be formed of any suitable material. In some applications, the balloon 12 may preferably be formed of polyethylene teraphthalate (PET) or may alternatively be formed of nylon or other suitable material.
One example of a balloon which is foldable in accordance with the present invention is that described in copending U.S. patent application Ser. No. 08/713,070 entitled Endovascular Delivery System. However, it will be appreciated that the balloon folding technique of the present invention will be useable with various types of balloons, as are used to radially expand various types of radially expandable intraluminal devices (e.g., stents, stented grafts, etc.).
The preferred method of folding the balloon 12 is shown in step-by-step fashion in FIGS. 2a-2g. As shown in FIG. 2a, the balloon 12 is initially deployed in its fully inflated configuration wherein the cylindrical sidewall 14 of the balloon 12 is disposed radially about a longitudinal axis LA which is projectable through the balloon 12 as shown in FIG. 1b.
As shown in FIG. 2b, a plurality of longitudinal furrows 18 (e.g., depressions, grooves, indentations, infoldings, invaginations, etc.) are formed in the sidewall 14 of the balloon 12, so as to define a plurality of balloon portions 20 between such longitudinal furrows 18. Such furrows 18 are preferably parallel, or substantially parallel, to the longitudinal axis LA of the balloon. Also, it is preferable that an even number of these longitudinal furrows 18 be formed in the balloon 12. In most cases, there will be a total of two (2), four (4) or six (6) longitudinal furrows 18 formed. In the particular example shown in the drawings, a total of four (4) longitudinal furrows 18a, 18b, 18c and 18d have been formed at equally spaced locations (e.g., 90 degrees, 180 degrees, 270 degrees and 360 degrees) about the sidewall 14 of the balloon 12. The formation of these four (4) longitudinal furrows 18a, 18b, 18c, and 18d has served to define a total of four (4) balloon portions 20a, 20b, 20c and 20d, between the respective furrows 18a, 19b, 18c and 18d.
Thereafter, as shown in FIG. 2c, each balloon portion 20a, 20b, 20c and 20d is pressed or collapsed into a flattened configuration.
Thereafter, each balloon portion 20a, 20b, 20c and 20d is overfolded, a first time, in the clockwise direction. (i.e. the direction indicated by the arrows shown in FIG. 2d). Such overfolding of the balloon portions 20a, 20b, 20c and 20d results in the formation of singly folded balloon portions 20a', 20b', 20c' and 20d', as shown in FIG. 2d.
Thereafter, each singly folded balloon portion 20a', 20b', 20c' and 20d' is overfolded, in the counterclockwise direction (i.e., the direction indicated by the arrows in FIG. 2e). Such overfolding of the singly folded balloon portions 20a', 20b', 20c' and 20d' results in the formation of doubly folded balloon portions 20a", 20b", 20c" and 20d", as shown in FIG. 2e.
Thereafter, if the mass of the balloon material permits, the doubly folded balloon portions 20a", 20b", 20c" and 20d" may be placed in alternating, overlapping disposition as shown in FIG. 2f. Such alternating, overlapping disposition may be achieved by causing the second and forth doubly folded balloon portions 20b", 20d" to lay over (e.g.,to bend or curl) in the counterclockwise direction, and subsequently causing the first and third doubly folded balloon portions 20a", 12c" to lay over (e.g.,to bend or curl) in the clockwise direction, such that they overlap in the manner shown in FIG. 2f.
Thereafter, a compressive jacket 24 is then formed about the balloon, to compress and flatten the balloon material. Depending on what material the balloon 12 is formed of, it may also be desirable to apply heat to the compressive jacket 24 to facilitate compression and/or flattening of the balloon material. Such compressive jacket 24 may comprise a wrapping of tape or other material about the balloon 12. Such wrapping may be accomplished by helically winding a strip or ribbon of plastic tape such as tape formed of polytetrafluoroethylene (PTFE), polyester, polypropylene or other suitable plastic for compressive wrapping about the balloon 12. Alternatively such compressive jacketing of the balloon 12 may be accomplished by advancing a tubular sleeve formed of material such as polyolefin, PVC or other suitable plastic, over the folded balloon 12 to form a compressive outerjacket 24 thereon. The compressive outer jacket 24 is then allowed to remain on the balloon 12 long enough to compress the balloon 12 sufficiently to permit the desired intraluminal device (e.g., stent, stented graft, etc.) to be mounded thereupon, in a radially collapsed configuration. Preferably, the intraluminal device is mounted on the compressed balloon 12 in a radially collapsed state of small enough diameter to allow the catheter 10 (with the radially compressed intraluminal device mounted thereon) to be transluminally advanced into the particular anatomical conduit in which the intraluminal device is to be implanted. It is to be appreciated that the invention has been described hereabove with reference to certain presently preferred embodiments or examples as shown in the drawings, and no effort has been made to exhaustively describe each and every embodiment in which the invention may exist. Indeed, numerous modifications could be made to the above-described embodiments without departing form the intended spirit and scope of the invention and it is intended that all such modifications be included within the scope of the following claim.
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Methods for folding a catheter mounted balloon, and delivery catheter systems which incorporate radially expandable intraluminal devices (e.g., stents, grafts and stented grafts) which are mounted on a balloon folded in accordance with this method. The method comprises generally folding the balloon at least twice, in opposite directions, so that any rotational forces created by the unfolding of the balloon as it is inflated will counteract each other, and will thus avoid substantial rotational movement of the intraluminal device during its radial expansion.
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TECHNICAL FIELD
The present disclosure relates generally to toroidal traction drives and more particularly to axial loading mechanisms for toroidal traction drives.
BACKGROUND OF THE INVENTION
Toroidal Continuous Variable Transmissions (“CVT”) are used to transmit rotational power from multiple sources, such as jet engines, to an electric generator. Toroidal traction drives use power rollers and toroids to translate rotational motion from the power rollers to a shaft by using the traction between the power rollers and the toroids. In order to generate sufficient traction between the toroids and the power rollers, an axial clamping force is applied to the toroids along an axis defined by the shaft thereby pressing the toroids against the power roller and allowing the power roller to transmit rotational power to the shaft. The input speeds from the multiple power sources generally vary within a certain speed range.
As the load on the shaft changes, the amount of axial clamping force required to maintain adequate traction between the power rollers and the toroids, and thereby ensure full power transmission to the shaft also changes. In some systems, the amount of clamping force required to maintain the traction can be predicted, and the clamping force can be gradually increased or decreased to compensate. In other systems, such as electrical generator systems, the load can change suddenly and unpredictably, requiring a fast response to maintain traction.
In one example, an axially loaded toroidal drive system uses a spring with a constant stiffness to provide a necessary axial loading force. In another example, an axial loaded toroidal drive system uses linear cam rollers to provide an adjustable axial load. Another example of an axial loading toroidal drive system uses a combination of a linear cam and a fixed spring to provide the axial load.
SUMMARY OF THE INVENTION
Disclosed is a toroidal traction drive having an axial loading system, where the axial loading system has a primary loading component and a non-linear cam roller loading component.
Also disclosed is an integrated drive generator for an aircraft. The integrated drive generator includes a toroidal traction drive generator operable to receive rotational power from at least one source; a shaft operable to output rotational power from the toroidal traction drive to an electrical generator. The toroidal traction drive comprises an axial loading system, where the axial loading system has a primary loading component and a non-linear cam roller loading component.
These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates an aircraft integrated drive generator system.
FIG. 2 schematically illustrates an example toroidal continuously variable transmission.
FIG. 2 a illustrates an alternative example toroidal continually variable transmission.
FIG. 3 illustrates an alternate input toroid for a toroidal continuously variable transmission.
FIG. 4A schematically illustrates a first non-linear cam in a minimum cam load position.
FIG. 4B schematically illustrates the first non-linear cam in an intermediate load position.
FIG. 4C schematically illustrates the first non-linear cam in a maximum load position.
FIG. 5A schematically illustrates a second non-linear cam in a minimum cam load position.
FIG. 5B schematically illustrates the second non-linear cam in an intermediate load position.
FIG. 5C schematically illustrates the second non-linear cam in a maximum load position.
FIG. 6A schematically illustrates a third non-linear cam in a minimum cam load position.
FIG. 6B schematically illustrates the third non-linear cam in an intermediate cam load position.
FIG. 6C schematically illustrates the third non-linear cam in a maximum cam load position.
DETAILED DESCRIPTION
FIG. 1 schematically illustrates an aircraft 10 having multiple turbine engines 20 . In the example shown, each turbine engine 20 is mechanically connected to two toroidal traction drives that are substantially similar such as, for example, toroidal traction drive 12 . The toroidal traction drive 12 converts rotation of the turbine engines 20 to rotation of a single shaft within the toroidal traction drive 12 . The shaft further translates its rotation to a generator 14 that generates electrical power, using known generator techniques, for supply to onboard electrical systems 16 .
FIG. 2 schematically illustrates the toroidal traction drive 12 of FIG. 1 in greater detail. The toroidal traction drive 12 includes a center shaft 120 and two pairs of power rollers 110 . Each of the power rollers 110 contacts an input toroid 122 and an output toroid 124 . Each of the toroids 122 , 124 exerts an axial force F or F′ on the corresponding power roller 110 to prevent the roller 110 from slipping and to ensure full translation of rotation from the power roller to the output toroid 124 , and thus to a gear. The force F is exerted along an axis A defined by the shaft 120 , and is referred to as axially loading the toroidal traction drive 12 . The input toroids 122 are slidably mounted on the shaft 120 using axial ball bearings 138 .
In order to ensure a correct axial load is applied, and thereby prevent slipping of the power rollers 110 regardless of the load on the shaft 120 , a hydraulic axial loading system and a roller cam axial loading system are incorporated in at least one of the input toroids 122 , and apply the axial load to the input and output toroids 122 , 124 . A constant spring 126 on a second end of the shaft 120 applies a counter-force F′ to the input and output toroids 122 , 124 . The counter-force F′ is dependent on the particular spring 126 utilized and the axial loading force F, and can be determined by one skilled in the art in light of the present disclosure.
The input toroid 122 on the end of the shaft 120 axially opposite the spring 126 includes multiple cam rollers 130 (the roller cam loading system) and multiple hydraulic pistons 132 (the hydraulic loading system) that are capable of controlling the axial load on the input and output toroids 122 , 124 . A hydraulic input port 134 provides hydraulic fluid through hydraulic passages 136 to the hydraulic pistons 132 , thereby allowing for control of the hydraulic pistons 132 by an outside controller. The hydraulic pistons 132 increase or decrease an axially aligned roller gap 340 , 440 (illustrated in FIGS. 4A-4C and 5 A- 5 C respectively) in the cam rollers 130 and thereby increase or decrease the axial loading, and control the traction between the power rollers 110 and the input and output toroids 122 , 124 . Similarly, the cam rollers 130 can rotate to increase or decrease the axial load provided by the cam rollers 130 by increasing the roller gap 340 , 440 according to known cam roller principles.
FIG. 3 illustrates an alternate input toroid 222 including an alternate axial loading system similar to the system illustrated in FIG. 2 . In the example illustrated in FIG. 3 , the hydraulic pistons 132 of FIG. 2 are omitted and the cam rollers 230 are sealed using an inner diameter seal 238 and an outer diameter seal 240 . Hydraulic fluid is pumped into or out of the roller gap 340 , 440 within the sealed cam rollers 230 , through a fluid input 234 on hydraulic passage 236 , thereby directly altering the roller gap 340 , 440 . Increasing the roller gap 340 , 440 increases the axial loading and decreasing the roller gap 340 , 440 decreases the axial loading. As with the example of FIG. 2 , the input toroid 222 in the example of FIG. 3 is mounted to the shaft via axial ball bearings 250
In alternate embodiments, non-hydraulic pistons such as piezo-electric pistons can be utilized in place of the hydraulic pistons 132 to affect the roller gap in the cam rollers 130 , 230 . FIG. 2 a illustrates the example system using a piezo-electric piston 132 a in place of the hydraulic piston 132 shown in FIG. 2 .
FIGS. 4A-4C partially schematically illustrate a cam roller 130 , 230 , using linear cam roller disks 310 , 320 and a non-linear (ovoid) bearing 330 to create a non-linear cam roller 130 , 230 . The non-linear nature of the illustrated cam roller 130 , 230 causes the force required to rotate the cam roller 130 , 230 to increase in an non-linear fashion as the cam roller 130 is rotated, thereby causing the rotational force on the cam roller 130 , 230 required to achieve a set axial load to increase in a non-linear fashion. FIG. 4A illustrates the cam roller 130 , 230 , in a minimum cam load position. The ovoid cam follower 330 contacts the top roller disk 310 and the bottom roller disk 320 at the lowest diameter 350 of the ovoid cam follower 330 , and the cam roller gap 340 is minimized. In the minimum axial load position, the rotational force required to increase the axial load is also minimized.
FIG. 4B illustrates the cam roller 130 , 230 in an intermediate axial cam load position. Relative to the minimum axial cam load position ( FIG. 4A ), the top cam roller disk 310 and the bottom cam roller disk 320 are rotated in opposite directions (counter-rotated). In an alternate example, only a single disk, either the first cam roller disk 310 or the second roller disk 320 , is rotated and the other cam roller disk 310 , 320 , is held stationary. The rotation of the roller disks 310 , 320 causes the non-linear bearing 330 to rotate to a position where an intermediate diameter 352 is contacting each roller disk 310 , 320 . As the diameter of the roller bearing 330 contacting the roller disks 310 , 320 increases, the rotational force required to further rotate the cam roller 130 , 230 increases. Similarly, as the cam follower approaches the peaks 312 , 322 in the roller disks 310 , 320 , the roller gap 340 is increased, thereby increasing the axial load on the input toroid.
FIG. 4C illustrates the cam roller 130 , 230 in a maximum cam load position. The top cam roller disk 310 and the bottom cam roller disk 320 have been further counter-rotated, and the largest diameter 354 of the cam roller bearing 330 is contacting each roller disk wall 310 , 320 . In the maximum load position, the cam roller 130 , 230 cannot rotate or increase the axial load, and all increased axial loading must be provided by the hydraulic loading system.
FIGS. 5A-5C illustrate another example non-linear cam roller bearing that can be used in the example toroidal traction drives 12 of FIGS. 1-3 . The example cam roller 130 , 230 of FIGS. 5A-5C uses a spherical cam follower 430 , and non-linear cam roller disks 410 , 420 . As with the example of FIGS. 4A-4C , counter-rotation of the top cam roller disk 410 and the bottom cam roller disk 420 causes the cam follower 430 to roll relative to the cam roller disks 410 , 420 , and thereby increase the cam roller gap 440 and the axial loading provided by the cam. The curved shape of the roller disks 410 , 420 in the example of FIG. 5 serves a similar function to the ovoid cam follower shape in the example illustrated in FIG. 4 , and causes the force required to rotate the roller disks 410 , 420 to increase as the bearing approaches the peaks 412 , 422 of the roller disks 410 , 420 .
By combining non-linear cam rollers 130 , 230 with a hydraulic loading system, the non-linear cam roller 130 , 230 reacts to load changes immediately, thereby providing a fast reaction time. However, due to the non-linear nature of the cam roller 130 , 230 , the cam roller 130 , 230 only reacts alone until the force required to further rotate the cam roller 130 , 230 is equalized with the hydraulic loading, at which point both axial loading systems (the cam roller 130 , 230 and the hydraulic loading) begin working together. Thus, the toroidal drive can achieve the reaction time benefit of a cam roller system, the resilience benefit of a hydraulic loading system, and both systems can work with repeated, unanticipated load changes.
FIGS. 6A-6C illustrate another example non-linear cam roller that can be used in the example toroidal traction drives 12 of FIGS. 1-3 . The example cam roller 130 , 230 of FIGS. 6A-6C uses cylindrical cam followers 530 having an ovoid cross section. The cylindrical cam follower 530 includes a plurality of gear teeth 532 on an outer circumference 534 of the cylindrical bearing 530 . The cam roller walls 510 , 520 likewise include a gearing portion 512 , 522 that interfaces with the teeth 532 on the cylindrical bearing 530 to prevent the cylindrical bearing 530 from slipping as force is applied to it.
A diameter 550 , 552 , 554 of the cam follower 530 is not constant, resulting in an oval shaped cam follower 530 , and gives rise to the non-linear behavior of the cam follower. In practice the cylindrical cam follower 530 of FIGS. 6A-6C and the ovoid shaped cam followers of FIGS. 4A-4C function similarly and provide the least axial loading force when the shortest diameter 550 of the cylindrical cam follower 530 is contacting the cam roller walls 510 , 520 , providing an intermediate axial loading when an intermediate diameter 552 is contacting the cam roller walls 510 , 520 , and providing a maximum loading when the largest diameter 554 is contacting the cam roller walls 510 , 520 .
Although example embodiments of this invention have been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this invention. A worker of skill in the art would also recognize that the above examples can be implemented alone or in any combination. For that reason, the following claims should be studied to determine the true scope and content of this invention.
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A toroidal traction drive has an axial loading system with a primary loading component and a non-linear cam roller loading component.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to a power supply detecting circuit capable of detecting a phase sequence of a polyphase power source.
[0003] 2. Description of Related Art
[0004] Three-phase power sources are common polyphase power sources used by grids worldwide to transfer power. Three-phase power is also used to power large motors and other large loads. A three-phase system is generally more economical because it uses less conductor material to transmit electric power than equivalent single-phase or two-phase systems at the same voltage. A typical three-phase power source includes three output terminals which reach their instantaneous peak values at different times. Taking one power rail as the reference, the other two power rails are delayed in time by one-third and two-thirds of one cycle of the electric current. The three-phase power source has the only phase sequence and the power rails of the three-phase power source should be correctly connects to power input terminals of the three-phase motors or the three-phase loads. However, the phase sequence of the three-phase power supply is sometimes unknown to users, which causes the motors or loads are connected to the power source incorrectly.
[0005] Therefore, what is needed, is a power supply detecting circuit capable of detecting a phase sequence of the polyphase power supply.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] Many aspects of the embodiments can be better understood with references to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the embodiments. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0007] FIG. 1 is a block diagram of a power supply detecting circuit according to an embodiment.
[0008] FIG. 2 is a detailed circuit of the power supply detecting circuit of FIG. 1 .
[0009] FIG. 3 illustrates waveforms of output powers rails of a three-phase power source.
DETAILED DESCRIPTION
[0010] The disclosure is illustrated by way of example and not by way of limitation. In the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.
[0011] In general, the word “module,” as used herein, refers to logic embodied in hardware or firmware, or to a collection of software instructions, written in a programming language, such as, for example, Java, C, or assembly. One or more software instructions in the modules may be embedded in firmware, such as an EPROM. It will be appreciated that modules may comprise connected logic units, such as gates and flip-flops, and may comprise programmable units, such as programmable gate arrays or processors. The modules described herein may be implemented as either software and/or hardware modules and may be stored in any type of computer-readable medium or other computer storage device.
[0012] Referring to FIG. 1 , an embodiment of power supply detecting circuit includes a converting module 10 , a control module 20 , and a phase sequence indicating module 30 . In one embodiment, the power supply detecting circuit is configured to detect a phase order of a three-phase alternative current (AC) power source which has three live wires and a neutral wire. The three live wires output three AC power rails which reach their instantaneous peak values at different times. Taking one power rail as the reference, the other two power rails are delayed in time by one-third and two-thirds of one cycle of the electric current.
[0013] Referring to FIGS. 2 and 3 , the converting module 10 includes a first signal converting circuit 11 , a second signal converting circuit 12 , and a third signal converting circuit 13 .
[0014] The first signal converting circuit 11 includes a first resistor R 1 , a second resistor R 2 , a third resistor R 3 , a first optical coupler U 1 , and a first capacitor C 1 . A first terminal of the first resistor R 1 is connected to a first live wire X 1 of the three-phase AC power source. A second terminal of the first resistor R 1 is connected to the first optical coupler U 1 . The first optical coupler U 1 includes a first light emitting diode (LED) D 1 and a first light sensitive transistor Q 1 . An anode of the first LED D 1 is connected to the first resistor R 1 . A cathode of the first LED D 1 is connected to the neutral wire N of the three-phase AC power source. The second resistor R 2 and the first LED D 1 are connected in parallel. A collector of the first light sensitive transistor Q 1 is coupled to a +5V direct current (DC) power via the third transistor R 3 . An emitter of the first light sensitive transistor Q 1 is connected to ground. The first capacitor C 1 is connected between the collector and the emitter of the first light sensitive transistor Q 1 . When a voltage output from the first live wire X 1 exceeds a predetermined threshold value U 0 (see FIG. 3 ), the first LED D 1 is lit. The first light sensitive transistor Q 1 is rendered conductive. The first signal converting circuit 11 outputs a low level voltage Y 1 (Y 1 =0V) to the control module 20 . When the voltage output from the first live wire X 1 is less than the predetermined threshold value U 0 , the first LED D 1 is powered off. The first light sensitive transistor Q 1 is rendered non-conductive. The first signal converting circuit 11 outputs a high level voltage Y 1 (Y 1 =+4.8V) to the control module 20 . In one embodiment, a resistance of the first resistor R 1 is much greater than that of the second resistor R 2 . Thus, a voltage drop across the first resistor R 1 is much greater than that across the second resistor R 2 , so that the first resistor R 1 can prevent overvoltage damage to the first LED D 1 .
[0015] The second signal converting circuit 12 includes a fourth resistor R 4 , a fifth resistor R 5 , a sixth resistor R 6 , a second optical coupler U 2 , and a second capacitor C 2 . A first terminal of the fourth resistor R 4 is connected to a second live wire X 2 of the three-phase AC power source. A second terminal of the fourth resistor R 4 is connected to the second optical coupler U 2 . The second optical coupler U 2 includes a second LED D 2 and a second light sensitive transistor Q 2 . An anode of the second LED D 2 is connected to the fourth resistor R 4 . A cathode of the second LED D 2 is connected to the neutral wire N of the three-phase AC power source. The fifth resistor R 5 and the second LED D 2 are connected in parallel. A collector of the second light sensitive transistor Q 2 is coupled to the +5V DC power via the sixth transistor R 6 . An emitter of the second light sensitive transistor Q 2 is connected to ground. When a voltage output from the second live wire X 2 exceeds the predetermined threshold value U 0 (see FIG. 3 ), the second LED D 2 is lit. The second light sensitive transistor Q 2 is rendered conductive. The second signal converting circuit 12 outputs a low level voltage Y 2 (Y 2 =0V) to the control module 20 . When the voltage output from the second live wire X 2 is less than the predetermined threshold value U 0 , the second LED D 2 is powered off. The second light sensitive transistor Q 2 is rendered non-conductive. The second signal converting circuit 12 outputs a high level voltage Y 2 (Y 2 =+4.8V) to the control module 20 . A resistance of the fourth resistor R 4 is much greater than that of the fifth resistor R 5 . Thus, the fourth resistor R 4 can prevent overvoltage damage to the second LED D 2 .
[0016] The third signal converting circuit 13 includes a seventh resistor R 7 , an eighth resistor R 8 , a ninth resistor R 9 , a third optical coupler U 3 , and a third capacitor C 3 . A first terminal of the seventh resistor R 7 is connected to a third live wire X 3 of the three-phase AC power source. A second terminal of the seventh resistor R 7 is connected to the third optical coupler U 3 . The third optical coupler U 3 includes a third LED D 3 and a third light sensitive transistor Q 3 . An anode of the third LED D 3 is connected to the seventh resistor R 7 . A cathode of the third LED D 3 is connected to the neutral wire N. The eighth resistor R 8 and the third LED D 3 are connected in parallel. A collector of the third light sensitive transistor Q 3 is coupled to the +5V DC power via the ninth transistor R 9 . An emitter of the third light sensitive transistor Q 3 is connected to ground. When a voltage output from the third live wire X 3 exceeds the predetermined threshold value U 0 (see FIG. 3 ), the third LED D 3 is lit. The third light sensitive transistor Q 3 is rendered conductive. The third signal converting circuit 13 outputs a low level voltage Y 3 (Y 3 =0V) to the control module 20 . When the voltage output from the third live wire X 3 is less than the predetermined threshold value U 0 , the third LED D 3 is powered off. The third light sensitive transistor Q 3 is rendered non-conductive. The third signal converting circuit 13 outputs a high level voltage Y 3 (Y 3 =+4.8V) to the control module 20 . A resistance of the seventh resistor R 7 is much greater than that of the eighth resistor R 8 . Thus, the seventh resistor R 7 can prevent overvoltage damage to the second LED D 2 .
[0017] In one embodiment, the first signal converting circuit 11 , the second signal converting circuit 12 , and the third signal converting circuit 13 have the same components and circuit connections.
[0018] The control module 20 includes a single chip microcontroller 22 with pins PA 0 -PA 7 (I/O pins) PB 0 -PB 7 (I/O pins) PC 0 -PC 7 (I/O pins) PD 0 -PD 7 (I/O pins) RESET (reset pin) VCC (power pin) GND (ground pin). The PB 2 pin is connected to the first signal converting circuit 11 for receiving the output signal Y 1 . The PD 2 pin is connected to the second signal converting circuit 12 for receiving the output signal Y 2 . The PD 3 pin is connected to the third signal converting circuit 13 for receiving the output signal Y 3 . A reset key K 1 is connected to the RESET pin of the single chip microcontroller 22 . The VCC pin is coupled to the +5V DC power. The GND pin is connected to ground.
[0019] The phase sequence indicating module 30 includes a first indicator LED 1 , a second indicator LED 2 , and a third indicator LED 3 . The indicators are different colored LED lamps. An anode of the first indicator LED 1 is connected to the PC 0 pin of the single chip microcontroller 22 . A cathode of the first indicator LED 1 is connected to ground via a tenth resistor R 10 . An anode of the second indicator LED 2 is connected to the PC 1 pin of the single chip microcontroller 22 . A cathode of the second indicator LED 2 is connected to ground via the tenth resistor R 10 . An anode of the third indicator LED 3 is connected to the PC 2 pin of the single chip microcontroller 22 . A cathode of the third indicator LED 3 is connected to ground via the tenth resistor R 10 .
[0020] To detect the phase sequence of the three-phase AC power source, the reset key K 1 is pressed, and the single chip microcontroller 22 starts to work. Then, the three-phase AC power source is switched on, and the live wires X 1 , X 2 , and X 3 start to output AC voltages. If the phase sequence of the three-phase AC power source is X 1 →X 2 →X 3 , the X 1 power rail firstly reaches the predetermined value U 0 . The first optical coupler U 1 is switched on. The output signal Y 1 from the first signal converting circuit 11 is at low level and sent to the PB 2 pin of the single chip microcontroller 22 . The PC 0 pin of the single chip microcontroller 22 outputs a high level voltage to the first indicator LED 1 . The first indicator LED 1 is lit firstly, while the second indicator LED 2 and the third indicator LED 3 are still powered off. After one third cycle, the X 2 power rail reaches the predetermined value U 0 . The second optical coupler U 2 is switched on. The output signal Y 2 from the second signal converting circuit 12 is at low level and sent to the PD 2 pin of the single chip microcontroller 22 . The PC 1 pin of the single chip microcontroller 22 outputs a high level voltage to the second indicator LED 2 . The second indicator LED 2 is lit after one third cycle while the first indicator LED 1 is still lit. After two third cycles, the X 3 power rail reaches the predetermined value U 0 . The third optical coupler U 3 is switched on. The output signal Y 3 from the third signal converting circuit 13 is at low level and sent to the PD 3 pin of the single chip microcontroller 22 . The PC 2 pin of the single chip microcontroller 22 outputs a high level voltage to the third indicator LED 3 . The third indicator LED 3 is lit after another one third cycle. Thus the first indicator LED 1 , the second indicator LED 2 , and the third indicator LED 3 are lit one by one in sequence; LED 1 →LED 2 →LED 3 . Then the phase sequence of the three-phase AC power source is X 1 →X 2 →X 3 . If the first indicator LED 1 , the second indicator LED 2 , and the third indicator LED 3 are lit one by one in a different sequence; L 2 →L 3 →L 1 , then the phase sequence of the three-phase AC power source is X 2 →X 3 →X 1 . If the first indicator L 1 , the second indicator L 2 , and the third indicator L 3 are lit one by one in yet another sequence; LED 3 →LED 2 →LED 1 , the phase sequence of the three-phase AC power source is X 3 →X 2 →X 1 . The power on sequence of the first indicator LED 1 , the second indicator LED 2 , and the third indicators LED 3 indicate the phase sequence of the three-phase AC power source being tested.
[0021] In one embodiment, the AC power source to be tested is a two phase, or four or more phase AC power source, and circuits similar to the above described detecting circuit can be utilized to detect the phase sequence of the polyphase AC power source.
[0022] While the present disclosure has been illustrated by the description of preferred embodiments thereof, and while the preferred embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications within the spirit and scope of the present disclosure will readily appear to those skilled in the art. Therefore, the present disclosure is not limited to the specific details and illustrative examples shown and described.
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A phase sequence detecting apparatus for a three-phase alternating current (AC) power includes a signal converting module and a phase sequence indicating module comprising plural indicating lights. The phase sequence detecting apparatus further includes a control module. The signal converting module is configured to receive three phase power signals output from the three-phase AC power, configured to convert the three phase power signals and send the converted signals to the control module. The control module controls power-on sequence of the indicating lights according to signals output from the signal converting module.
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FIELD OF THE INVENTION
[0001] The present invention relates to dice, and more particularly, relates to dice with magnets therein and games which utilize magnetic dice.
BACKGROUND OF THE INVENTION
[0002] Dice have long been used in games of chance and in a wide range of games and other activities. Although typically a die, or dice will have 6 sides of equal and identically shaped surfaces (generally squares, or slightly rounded squares) with generally straight or slightly rounded edges, it is also common to have dice with non-square surfaces (for example, an eight sided die, each side of which is an equilateral triangle), and although less common, other dice in which some of the surfaces are of a different shape or size than other of the surfaces on the dice. In some games, two or more dice are thrown simultaneously, the outcome of the game depending on, for example, the number, image or information presented on those surfaces of the thrown dice when all movement of the dice has stopped. While there may be some physical interaction between the two or more dice after they are thrown (for example, two die may collide with, and thereby affect one another), these physical interactions are limited as they depend upon an actual collision between the two or more dice, which may or may not occur on any particular throw. Additionally, some games have been developed in which the dice, rather than presenting numbers or letters to the game players, instead present images, and for example, instructions.
[0003] It is desirable to have dice that will interact with each other whether or not there is an actual physical collision between the dice. It is also desirable to have dice games in which the magnetic interaction of the dice will have an impact on the progress or outcome of the game. It is also desirable to have magnetic dice which, as a result of the magnetic attraction between magnets in two dice, may magnetically engage with one another, the engagement surfaces of the two dice providing game information from which a game of dice may progress or be determined. It is also desirable to have a battle game using magnetic dice which have a predetermined initial number of lives, and which, during the progression of the game, lose lives until one die has no more lives, thereby determining the outcome of the game.
SUMMARY OF THE INVENTION
[0004] Accordingly, one object of the present invention is to provide dice which can, after they are thrown, interact with one another, whether or not there are any physical collisions therebetween.
[0005] Accordingly, another object of the present invention is to provide dice games in which the magnetic interaction of the dice will have an impact on the progress or outcome of the game.
[0006] Accordingly, another object of the present invention is to provide magnetic dice which, as a result of the magnetic attraction between magnets in the dice, may magnetically engage with one another, the engagement surfaces of the two dice providing game information from which a game of dice may progress or be determined.
[0007] Accordingly, another object of the present invention is to provide a battle game using magnetic dice which have a predetermined initial number of lives, and which, during the progression of the game, lose lives until one die has no more lives, thereby determining the outcome of the game.
[0008] According to one aspect of the present invention, there is provided a die comprising, at least four surfaces, and at least one magnet, wherein the at least one magnet is in secure engagement with the die and having magnetic effect which extends beyond a surface of the die.
[0009] According to another aspect of the present invention, there is provided a game of dice for multiple players comprising, at least two multi-surfaced dice, each of the at least two multi-surfaced dice having game information on at least one surface thereof relating to the initial number of lives for each of the at least two multi-surfaced dice, and having game information on at least one surface thereof for determining the number of lives to be deducted from the then current number of lives on at least one other die, the dice being flicked or thrown by the players to determine the reduction of lives of at least one other die until at least one die no longer has any lives.
[0010] The advantage of the present invention is that it provides dice which can, after they are thrown, interact with one another, whether or not there are any physical collisions therebetween.
[0011] Another advantage of the present invention is that it provides dice games in which the magnetic interaction of the dice will have an impact on the progress or outcome of the game.
[0012] Another advantage of the present invention is that it provides magnetic dice which, as a result of the magnetic attraction between magnets in the dice, may magnetically engage with one another, the engagement surfaces of the two dice providing game information from which a game of dice may progress or be determined.
[0013] Another advantage of the present invention is that it provides a battle game using magnetic dice which have a predetermined initial number of lives, and which, during the progression of the game, lose lives until one die has no more lives, thereby determining the outcome of the game.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] A preferred embodiment of the present invention is described below with reference to the accompanying drawings, in which:
[0015] FIG. 1A is a view of one embodiment of the arrangement of 6 magnets used on a partially completed six sided die of one embodiment of the present invention;
[0016] FIG. 1B is a view of one embodiment of the unmarked die of FIG. 1A where the die surfaces have been completed;
[0017] FIG. 2A is an alternative embodiment of the arrangement of 6 of the 6 magnets used on a partially completed six sided die of one embodiment of the present invention;
[0018] FIG. 2B is a view of a magnet for use in the six sided die of FIG. 2A ;
[0019] FIG. 2C is a view of the magnets positioned within the six sided die of FIG. 2A ;
[0020] FIG. 3 is a view of a die of one embodiment of the present invention with battle game markings thereon;
[0021] FIG. 4A is a view of a die of one embodiment of the present invention with alternative battle game markings thereon;
[0022] FIG. 4B is a view of a die of one embodiment of the present invention with further alternative battle game markings thereon;
[0023] FIG. 4C is a view of a die of one embodiment of the present invention with further alternative battle game markings thereon;
[0024] FIG. 4D is a view of a die of one embodiment of the present invention with further alternative battle game markings thereon;
[0025] FIG. 5 is a playing surface for a battle game of one embodiment of the present invention;
[0026] FIG. 6 is a sample scoring sheet for one embodiment of the battle game of one embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] In a preferred embodiment of the present invention, dice are provided which have permanent magnets (hereinafter “magnets”) securely positioned therewithin, such as, for example as illustrated in the embodiment shown in FIG. 1B , or alternatively in the embodiment shown in FIG. 2C , in the preferred embodiment, the magnets being positioned so that one surface of the magnet is at or near the surface of the die, the magnetic effect of the magnets extending beyond the surface of the die (it being understood, that for example, in alternative embodiments of the present invention, the magnets may not extend to the surface of the dice, but may nevertheless have sufficient strength to extend their magnetic effect to and beyond the surface of the die). For example, as illustrated in FIG. 1A , six disc-shaped magnets 2 , 4 , 6 , 8 , 10 and 12 are securely attached to a solid six sided cube 14 , and thereafter plastic 16 , ceramic or other non-magnetic non-conducting material is positioned around the magnets and shaped to provide a rounded six-sided cube such as is illustrated in FIG. 1B , the height, width and depth of the cube preferably being 30 mm, it being understood that alternatively sized cubes may be used in alternative embodiments of the present invention. In an alternative embodiment as illustrated in FIGS. 2A and 2C , holes 14 , 16 , 18 , 20 , 22 and 24 are provided in the surfaces 2 , 4 , 6 , 8 , 10 , and 12 respectively, into which holes 14 , 16 , 18 , 20 , 22 and 24 are securely positioned magnets 28 , 30 , 32 , 34 , 36 , and 38 (such as the one illustrated in FIG. 2B ) respectively. It is understood that in alternative embodiments of the present invention, dice having fewer than six sides, or more than six sides may be provided. Furthermore, it is understood that in alternative embodiments of the present invention, various different methods may be used to securely position magnets within, or in relation to the dice, so that magnets are securely positioned, and the magnetic effect of the magnets extends beyond the surface of the dice. The non-magnetic portions of the dice may be made of plastic, wood, acrylic, vinyl or such other non-magnetic, non-conducting material as would be known to a person skilled in the art.
[0028] Within a particular die, the north-south orientation of the magnets may be varied, from all magnets oriented to expose outwardly a north pole, to all magnets oriented to expose outwardly a south pole, or any combination of pole orientations within that range. Furthermore, each die in a set of dice may either have the same combination of pole orientations as the other dice within the set, or it may also vary across a wide range of possible combinations of orientations. In this way, depending upon the orientation of the poles of the magnets within the dice, the dice (or any surface thereof) may attract or repel each other (or any surface thereof), depending upon the proximity and orientation of the dice relative to each other, and of the orientation of the poles of the magnets within one die which are proximate to the other dice.
[0029] In the preferred embodiment, relatively strong magnets are used, the magnets being in disk form, with a diameter of 12.7 mm and a thickness of 3.2 mm. In an alternative embodiment, less strong magnets are used, the magnets also being in disk form, with a diameter of 20 mm and a thickness of 5 mm it being understood that differently shaped and differently sized magnets may used in different embodiments of the invention.
[0030] In a preferred embodiment of the present invention, magnetic dice of the present invention have preferably painted or printed on or otherwise affixed to one or more surfaces thereof, graphical information and/or game information and/or game data and/or game instruction for use by the game users.
Battle Game Using Magnetic Dice
[0031] A wide variety of different games may be played utilizing the dice of the present invention. In one game, hereinafter referred to as the “Battle Game”, each surface of each of the dice used in the Battle Game preferably has graphical information and/or game information and/or game data and/or game instruction thereon specifically related to the Battle Game such as is illustrated in FIG. 3 (the various surfaces of the die preferably having a variety of different graphical information and/or game information and/or game data and/or game instruction thereon). For the purposes of the description of the Battle Game as described herein, each die having graphical information and/or game information and/or game data and/or game instruction thereon specifically related to the Battle Game will be referred to herein as a “block”. In the preferred embodiment of the Battle Game of the present invention (it being understood that various different versions or modification may be made to this game as may be desired), the preferred rules and gameplay of which are hereinafter provided, each player uses a single block, which block will have a predetermined initial number of “Lives” with which to start the game (the initial number of lives for each block is identified on each block, such as is illustrated in FIG. 3 at 32 where on that block the indicia “LIFE 10” indicates that that block will start the game with 10 lives). In this embodiment of the game, game information provided on the surfaces of the block is used in the context of the game and includes, for example, an “Attack Number” (as illustrated in FIG. 3 , in the preferred embodiment, the Attack Numbers 31 and 34 are preceded by the letter “A”, the Attack Numbers 31 and 34 in respect of the block illustrated in FIG. 3 being “4” and “3” respectively), and a “Defense Number” (in the preferred embodiment, the Defense Numbers 30 , 33 and 37 are preceded by the letter “D”, the “Defense Numbers 30 , 33 and 37 in respect of the block illustrated in FIG. 3 being “2”, “1” and “2” respectively) are provided. In some cases, additional or alternative numbers, such as “Special Attack Numbers” (the Special Attack Numbers 35 are preceded by the letters “SPA” (the Special Attack Number 35 in respect of the block illustrated in FIG. 3 being “5”), “Reverse Attack Numbers” (the reverse attack numbers 114 , for example, may be preceded by the letter “R” as illustrated in FIG. 4D ) and/or other information is also provided.
[0032] In this embodiment of the present invention, the Battle Game is played on a playing surface 201 made of cardboard or plastic or other suitable material such as is illustrated in FIG. 5 , having two sides 198 and 199 , one side for each player, each player's side having an Attack Line 200 and 202 marked thereon (it being understood that in alternative embodiments of the present invention, the markings such as those illustrated in FIG. 5 may be painted, or marked with chalk, or with other marking devices (such as one or more flags, coloured or uncoloured strings (which can be weighted or not as needed), painted markings, the chalk markings, the flags and strings being marked to indicate the attack lines and defense line) on a wide range of surfaces, such as concrete, wood, asphalt, or other suitable surface as would be known to a person skilled in the art). A Defense Line 204 is marked at a position equally distant from the Attack Lines 200 and 202 . In the preferred embodiment of the present invention, the distance between the Attack Lines and the Defense Line is approximately 40 inches, it being understood that a range of different distances may be used in alternative embodiments of the present invention. In an alternative embodiment of the present invention, a surface of pre-determined size, shape and materials is provided for the purposes of formalizing and regularizing gameplay. In this embodiment of the invention, one or more attack lines may be printed or otherwise displayed on the game surface, permitting the players to choose from between a range of different attack lines.
[0033] In normal play, in the preferred embodiment of the Battle Game, the two players chose their Attack Line and position themselves behind their respective Attack Lines, and roll their block to determine which player will start the game in Attack Mode and which player will start the game in Defense Mode, the player (hereinafter the “First Player”) rolling the highest Attack Number (as that term is more fully described herein) starts first in Attack Mode and the other player (hereinafter the “Second Player”) starts first in Defense Mode, the players subsequently alternating between being in Attack Mode and Defense Mode as more fully described herein. The Second Player positions his/her block (hereinafter the “Second Player's Block”) on the Defense Line, and the First Player thereafter flicks his/her block (hereinafter the “First Player's Block”) (a flick of a block in the preferred embodiment of the game of the present invention being the act of positioning the block on the game surface on or behind the flicker's Attack Line, the flicker cocking his/her index or middle finger with his/her thumb behind the block and thereafter releasing the cocked finger in the direction of, and to impact with the block to thereby move the block away from the flicker's hand) in the direction of the Defense Line. In the event that after the flick of the First Player's Block, the First Player's Block and the Second Player's Block are not in magnetic engagement with one another, the Second Player's Block is removed from the playing surface, and the First Player's Block is positioned on the Defense Line in the same orientation as that Block came to rest after the flick. The First Player switches to Defense Mode, and Second Player switches to switches to Attack Mode, the Second Player thereafter flicking his/her Block in the manner as described above. This flicking and alternating process repeats until such time as the First Player's Block and Second Player's Block are in magnetic engagement with one another.
[0034] In the event that a flick results in the First Player's Block and Second Player's Block being in magnetic engagement with one another, an examination is made of the two surfaces of the Blocks which became magneticly engaged with one another. In the event that there is no “Reverse Attack” 116 indicated on the engaged surface of the Block of the player then in Defense Mode, then if the Attack Number on the engaged surface of the Block of the player then in Attack Mode (or in the event that a Special Attack Number appears on the engaged surface of the Block of the player in Attack Mode, the “Special Attack Number”) exceeds the Defense Number on the engaged surface of the Block of the player then in Defense Mode, the number of lives corresponding to the difference between these values is removed from the current number of lives on the Block of the player then in Defense Mode. If this does not result in that Block having zero or fewer lives, the players switch modes (unless the Special Attack directs the player then in Attack Mode to “Roll Again” 35 such as is illustrated on the surface of the Block illustrated in FIG. 3 , in which case the person then in Attack Mode remains in Attack Mode for another flick and the person in Defense Mode continues in Defense Mode for another flick) and the game continues as described above. In the event that there is a “Reverse Attack” indicated on the engaged surface of the Block of the player then in Defense Mode, then if the Reverse Attack Number on the engaged surface of the Block of the player then in Defense Mode exceeds the Defense Value on the engaged surface of the Block of the player then in Attack Mode, the number of lives corresponding to the difference between these values is removed from the current number of lives on the Block of the player then in Attack Mode. If this does not result in that Block having zero or fewer lives, the players switch modes and the game continues as described above.
[0035] In the event that the Attack Number on the surface of the Block of the player then in Attack Mode does not exceed the Defense Number on the surface of the Block of the player then in Defense Mode, then no lives are removed from the current number of lives on the Block of the player then in Defense Mode, the Block of the player then in Attack Mode is then positioned on the Defense Line in the same orientation as that Block came to rest after the flick, the players switch modes, and the game continues as described above.
[0036] If at any time during the game, a Block comes to have zero or fewer lives, the game is over, and the player whose Block still has lives is victorious in the game.
[0037] In one embodiment of the Battle Game of the present invention, in the event that the attacking Block comes to rest on top of the defending Block, the defending Block automatically loses all of its lives, and the game is over, the player then having the attacking Block being victorious in the game.
[0038] It is understood that in various embodiments of the present invention, a wide range of game information and graphical information may be displayed in various forms and styles on the surfaces of the blocks, several examples of which are illustrated in FIGS. 4A , 4 B, 4 C and 4 D, which blocks also provide Attack Numbers 44 , 52 , 58 (in the case of the block of FIG. 4A ), 66 , 68 , 74 (in the case of the block of FIG. 4B ), 80 , 90 , 94 (in the case of the block of FIG. 4C) and 102 , 104 , 110 (in the case of the block of FIG. 4D ), Defense Numbers 46 , 54 , 56 (in the case of the block of FIG. 4A ), 64 , 70 , 76 (in the case of the block of FIG. 4B ), 84 , 88 , 96 (in the case of the block of FIG. 4C ), which latter block also includes the notation “Roll Again” 82 , and 98 , 108 (in the case of the block of FIG. 4D ), which latter block also includes the notation “Reverse Attack” 112 and provides a Reverse Attack Number “4” 114 .
[0039] In one embodiment of the present invention, using a scoresheet such as illustrated in FIG. 6 , the players can record the current number of lives that their block has at any given time, until such time as one of the blocks no longer has any lives, whereupon the game is concluded. In the embodiment of the scoresheet of FIG. 6 , two columns 300 and 302 are provided, one for each player, into the first row of which the player's name (for example “Jonny” 301 and “Anne” 303 ) is recorded, and thereafter, in the next row of each column, the initial number of lives (for example “11” 304 and “8” 306 ) of the block being used by that player is recorded. In this embodiment of the scoresheet, as the game progresses, whenever a player's block loses one or more lives, the number of lives lost is recorded in the upper left corner of the next unused cell in that player's column (for example, if Jonny's block were to lose 4 lives, the number “4” 308 is recorded in the upper left corner of the cell) and the remaining number of lives for that block is also recorded in the center of that cell (in this example, the number “7” 310 is recorded in the center of that cell). This continues until the block of one of the players has no lives remaining, in which case, in this embodiment of the invention, the number “ 0 ” 312 is recorded in the appropriate cell for that player, and the word “WIN” entered in the adjacent cell for the winning player. In this embodiment of the invention, a line 316 may be drawn on the scorecard, and the next game can be recorded in a similar manner in the unused portions of the columns below the line 316 in a manner known to a person skilled in the art. It is understood that a wide range of different score sheets and mechanisms may be used to record the progress and outcome of the Battle Game of the present invention, as would be known to a person skilled in the art. In an alternative embodiment of the present invention, each of the blocks has contained therewithin, a small movable click wheel upon which a series of numbers is printed or displayed (the numbers corresponding to the number of lives remaining for that block), the click wheel being positioned so that it can be rotated manually by the players to outwardly display the then current number of lives of their block.
[0040] In an alternative embodiment of the present invention, an electronic battle surface is provided, in which embodiment the battle surface will electronically keep track of the current number of lives of the blocks. In one embodiment of the present invention, sensors are positioned to determine whether one block comes into contact with the other block, which sensors will trigger a pre-determined sound to be played to provide auditory emphasis to the contact between the blocks.
[0041] In an alternative embodiment of the present invention, each block has a power supply, such as a battery or other similar device embedded therewithin, and each side of each of the blocks has a button thereon used to connect to an electronic circuit, which button will be temporarily depressed as a result of two blocks becoming magnetically engaged with one another, and which button, when depressed, will activate the electronic circuit, which circuit will electronically communicate the Attack Number, Defense Number and other data and information to an electronic score/life tracking display, thereby permitting the current number of lives of each block to be recorded and displayed electronically. In a further alternative embodiment, a Light Emitting Diode or other light source is embedded in each corner of the block, a micro processor also embedded within the block providing control to the Light Emitting Diodes to thereby provide various lighting effects for the block. It is understood that a wide range of different electronic score/life recording and displaying and appearance altering mechanisms can be provided in accordance with the present invention.
[0042] It is understood that the dice of the present invention may be varied and utilized in the context of playing a wide variety of different games as would be known to a person skilled in the art.
[0043] The present invention has been described herein with regard to preferred embodiments. However, it will be obvious to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as described herein.
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A game of dice for multiple players comprising, at least two multi-surfaced dice, each of the at least two multi-surfaced dice having game information on at least one surface thereof relating to the initial number of lives for each of the at least two multi-surfaced dice, and having game information on at least one surface thereof for determining the number of lives to be deducted from the then current number of lives on at least one other die, the dice being flicked or thrown by the players to determine the reduction of lives of at least one other die until at least one die no longer has any lives.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 10/757,880, filed Jan. 14, 2004, for “Electrical Generator Fluid-Flow-Coolant Filtration”, now U.S. Pat. No. 7,150,431 B2, granted Dec. 19, 2006, the entire content of which is hereby incorporated herein by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to management of the flow of coolant fluid (typically air) to an electrical generator in a vehicle, and in particular to the filtering of such flow which is directed ultimately to the sliding-contact electrical interface region, or zone, in such a generator. While the invention is believed to have applicability in a number of different vehicle settings, a preferred and best mode embodiment of, and manner of practicing, the invention are described herein generally in the context of aircraft, and more particularly in the context of a specific aircraft model wherein the invention has been found to offer significant utility.
In this context, a problem has existed with regard to the operation of certain aircraft relating to unexpectedly early, catastrophic failure of on-board electrical generators—a failure which potentially can be quite dangerous. Not only that, such generators, i.e., those employed in aircraft, can be very expensive pieces of equipment, and a catastrophic failure almost inevitably leads to a requirement for wholesale, costly replacement. The magnitude of this expense problem multiplies appreciably where an aircraft employs more than one electrical generator.
The specific failure herein being referred to involves catastrophic wear in what can be thought of as the electrical sliding-contact zone in a generator of the type mentioned—the zone involving the contact interface between brushes and a commutator, or between brushes and rings. A normal operating condition which is expected in this region is relatively long-term modestly progressive wear of the brushes—components which are expected to require replacement only occasionally, and replacement at a relatively low cost. What is definitively not expected is rapid, noticeable wear of a commutator or rings, let alone early catastrophic wear of these components which are usually and decidedly not intended to require major repair or replacement during the normal, expected working lifetime of a generator. Even more strikingly puzzling is the occurrence of such wear under circumstances wherein there is little evidence of brush wear. Yet, this is exactly the startling manifestation which characterizes the issue to which the present invention is directed.
Until the making of the discovery which has led to the creation of the present invention, experts were baffled by the mentioned wear problem, and indeed even more baffled by the fact that none could discern the cause of the problem. Deciphering of the problem was, to say the least, not intuitive.
Discovery came to me eventually by my taking a very close look at the substantially “non-worn” brushes. This look ultimately enabled me to uncover the culprit. Embedded in the contact face of each examined brush was a dense population of tiny abrasive grit whose presence, I soon determined, effectively reversed the intended, normal wear behavior of the electrical sliding-contact interface region in the failed generator which I was examining. The brushes, with this “illusive” embedded grit in place, were effectively acting in generators like abrader tools—grinding and machining away the working surface(s) of associated commutators/rings. Further examination and contemplation revealed that the primary source of this grit was engine-exhaust particulate content which found its way into the flow of coolant air (fluid) directed toward the contact interface region of the brushes.
Accordingly, and in response to these discoveries, proposed by the present invention is a special ventilation, or coolant, fluid-flow management methodology implemented by a system which effectively eliminates these discovered exhaust-grit problems.
Further elaborating, in the operating environment of an aircraft, and with the system illustrated herein which implements the present invention installed and operating, when the engine is running, and the aircraft is flying, an air intake collects an inflow of air and feeds it into the intake end of a fluid conduit system, the discharge end of which (or ends if more than one electrical generator is/are involved) is/are tightly coupled to (via a fluid-flow connection which closes upon) the electrical sliding-contact (brush, etc.) zone(s) in the generator(s). Intermediate the intake and discharge ends of this special implementing conduit system, in accordance with the invention, is a filter, or a filter structure, which blocks the passage of harmful grit, such as exhaust grit, which may be present in this air flow. Such grit, as I have discussed, puts the electrical sliding-contact zone of an aircraft generator at serious risk—evidenced by surprising degradation of commutator or ring structure in the generator.
Additionally, upstream from this filter structure is an air-flow expansion chamber which acts to retard air-flow velocity, and to expand the cross-sectional area of this retarded flow, thus to improve filtering action. Adjacent the base of the filter structure is a gravity-functioning trap and drain which collects and discharges moisture in the fluid flow adjacent the filter structure.
Installation and operation of this system which carries out the methodology of the invention effectively eliminates the catastrophic wear and failure problem to which the invention is addressed.
These and other important features and advantages which are offered by the methodology of the present invention will become more fully apparent now as the description which shortly follows is read in conjunction with the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified, fragmentary side-elevation (from the outside) of the nose engine compartment of an aircraft which is equipped with a fluid-flow management system constructed to implement, and thus to function in accordance with, a preferred and best-mode embodiment of, and manner of practicing, the present invention.
FIG. 2 is a schematic illustration of the methodology-implementing fluid-flow management system which is installed in the aircraft of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings (both figures), indicated generally at 10 in FIG. 1 is the nose engine compartment of an aircraft 12 in which a preferred and best mode embodiment of the invention has been installed (the engine is not illustrated). This embodiment implements the methodology of the invention. As was mentioned earlier, while the present invention may well have utility in various different kinds of vehicles, it has been found to furnish significant utility in a particular aircraft model, and thus is principally illustrated and described herein in such an aircraft. This aircraft is a Pilatus model PC-12 aircraft, and accordingly that specific model of aircraft is referred to herein for the purpose of disclosure and illustration of the invention.
Exposed on the outside of the engine housing provided for nose compartment 10 in FIG. 1 are an engine exhaust outlet 14 . Disposed rearwardly thereof (to the right in FIG. 1 ), there is also provided an air-flow inlet, or intake, 16 . Flight direction for aircraft 12 is indicated by an arrow 13 , exhaust direction by an arrow 15 , and airflow intake direction by an arrow 17 .
Intake 16 is coupled to an on-board ventilating air-flow management system constructed in accordance with the present invention to implement the methodology of the invention. This system is generally indicated at 18 in FIG. 2 . In aircraft 12 , system 18 provides airflow management for two electrical generators (or generating devices) shown generally at 20 , 22 in FIG. 2 . The specific downstream location in nose 10 of air intake 16 relative to exhaust outlet 14 is not a configuration dictated by the present invention. Rather, it is dictated by the particular manufacturing architecture which has been chosen by the maker of the aircraft model mentioned above. It should be understood that the methodology of the present invention is not limited to this specific aircraft model, and is useful no matter what the engine-exhaust/air-intake geometry turns out to be. The location of air intake 16 is referred to herein as being functionally upstream from the locations of generators 20 , 22 .
Looking specifically at FIG. 2 , system 18 further includes a fluid-flow conduit structure 24 , which, as illustrated herein, includes (a) an intake conduit section 26 which defines an intake end in this system, and which is fluid coupled to air intake 16 , (b) a flow velocity-modifying structure 28 having a flow-expansion chamber, or plenum, 28 a coupled to conduit section 26 , and a flow contraction chamber, or plenum, 28 b , (c) a gravity-operable liquid trap and drain structure 30 disposed adjacent the base of structure 28 intermediate chambers 28 a , 28 b , and (e) a pair of discharge conduit sections 34 , 36 which collectively define a discharge end (or ends) for the conduit structure, and which interconnect conduit section 32 and generators 20 , 22 , respectively. Specifically, conduit sections 34 , 36 couple ventilating airflow through suitable connectors 38 , 40 , respectively, to the brush regions, also called the electrical sliding-contact zones, 20 a , 22 a , respectively in generators 20 , 22 . Zones 20 a , 22 a are shown as shaded regions in FIG. 2 . Connectors 38 , 40 may be of any suitable design appropriate to the configurations of the generators, and do not form part of the present invention. In the absence of connectors 38 , 40 which close upon zones 20 a , 22 a , these zones, undesirably, would be nominally exposed to otherwise uncontrolled, un-grit-filtered airflow. Closure of connections 38 , 40 on zones 20 a , 22 a , respectively, in addition to being discussed herein, is illustrated graphically in FIG. 2 .
Disposed within structure 28 , just above trap and drain structure 30 , which drains liquid to the outside of aircraft 12 as indicated by arrow 42 , is a filter, or filter structure, 44 . This filter is preferably structured to block the passage into conduit section 32 , and thus ultimately into zones 20 a , 22 a via closure connectors 38 , 40 , of substantially all particles, such as the mentioned, damaging grit particles. The specific structure of the filter is conventional, and is not part of the present invention. A filter structure which has been found to work well in the specific aircraft mentioned above is a foam filter made by Brackett Aero Filters, Inc., of Kingman, Ariz., Model No. BA-5110.
With this arrangement as just described, substantially all ventilating airflow which is provided to zones 20 a , 22 a is delivered by system 18 , and through filter 44 , and is then close-coupled to these zones through connections 38 , 40 .
Freely choosable by one implementing the present invention is the specific location for filter 44 . Cleaning and/or replacing of a filter is accommodated by the fact that structure 28 is selectively openable (in any suitable manner). Expansion of airflow in chamber 28 a to slow down airflow velocity, and to enlarge the cross-sectional area of that flow, immediately upstream from the filter aids by causing airflow to spread out across a broad filtration surface, thus to improve filtration effectiveness and operational filter lifetime. Gravity liquid trap and drain structure 30 discharges collected moisture/liquid downwardly through an appropriate drain structure (not shown) disposed on the underside of aircraft nose 10 .
As stated earlier herein, the methodology of this invention effectively eliminates the serious catastrophic failure problem previously described above herein. The particular system shown and described herein which implements this methodology is quite simple in construction, and can be quite inexpensive in its making, installation and implementation. It can very easily be incorporated not only in new construction, but also as retrofit structure in an existing aircraft.
The methodology of the invention can be described as (a) intaking a flow of air at a location which is functionally upstream from an electrical generator in an aircraft, (b) filtering the thus intaken airflow to block the passage of entrained solids (particles), and (c) directing the filtered airflow in a close-coupled manner into the electrical sliding-contact zone of the electrical generator (or generators) in the aircraft, whereby that particle-and-grit-filtered flow, as a consequence of such close-coupling, provides substantially all of the ventilating air-flow which enters that zone. Where the word “aircraft” is employed herein, it should be understood to include other forms of vehicles wherein the problem addressed by the present invention may exist.
While a preferred and best mode embodiment of, and manner of practicing, the invention have thus been described and illustrated herein, it is appreciated that variations and modification may be made without departing from the spirit of the invention.
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A ventilating and particle-filtering airflow methodology for managing the flow of air to the electrical sliding-contact zone of an on-board aircraft (vehicle) electrical generator. Conduit structure collects intaken air during aircraft (vehicle) engine operation, filters this air to capture and prevent the passage of particles, and directs filtered airflow to that brush region through a close-coupled fluid-flow connection which closes upon and substantially isolates (in terms of incoming airflow) that region. Water drainage is provided for in a region near where filtering takes place. The filtered airflow is substantially the only airflow admitted to this protected region.
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FIELD OF THE INVENTION
[0001] The invention relates to fluoropolymers, and in particular polyvinylidene fluoride (PVDF) polymers that are stabilized against color degradation due to high thermal exposure. The fluoropolymers of the invention are produced with free-radical initiators in the presence of surfactants containing acid end groups—such as sulfonic acid. The fluoropolymer resins are melt processed into final articles at high temperatures, above the melting point of the polymer. While the fluoropolymer is stable, residual acid surfactant causes discoloration during thermal processing. Stabilization is achieved by the addition of small amounts of ammonium or phosphonium cations to the fluoropolymer composition. It is believed the cations react with any residual acid to form a less reactive salt. These salts do not adversely affect the color of a melt processed product. The phosphonium or ammonium ions in the form of an organic or inorganic salt can be added to the fluoropolymer at any point from the polymerization step up to the thermal processing step. A preferred family of salts are quaternary alkyl ammonium halides.
BACKGROUND OF THE INVENTION
[0002] Fluoropolymer resins possess various favorable physical properties such as marked toughness and high elasticity. They are resistant to harsh environments and provide weatherproof properties. They are widely used in both coating and melt-processable applications. In melt-processing applications, polyvinylidene fluoride (PVDF) can be easily processed on standard equipment without the need for extrusion aids, such as lubricants. These fluoropolymers are melt-processed to form polymer structures by many different processes, such as extrusion, coextrusion, injection molding, and blow molding
[0003] Good physical properties are generally maintained by PVDF and polyvinyl fluoride (PVF) during the long heat history processes without the aids of heat stabilizers, though undesired discoloration can sometimes occur as a result of thermal processing.
[0004] Many methods have been proposed to reduce discoloration of fluoropolymers during the formation of articles and coatings. Many of these involve changes in the synthesis through a choice of initiator (U.S. Pat. No. 3,781,265), and (JP 58065711); special chain transfer agents (U.S. Pat. No. 4,569,978) (U.S. Pat. No. 6,649,720) and (EP 655468); delayed comonomer feeds (U.S. Pat. No. 6,187,885); and specific surfactants (EP 816397).
[0005] Improved properties for fluoropolymers have also been reported by the post-polymerization addition of additives such as octyltin compounds (JP62018457); zinc oxide additives (JP47038058); a phosphate and/or phosphonite processing stabilizer with a phenol antioxidant and a nucleating agent (GB2261667); a polyester plasticizer, phosphite and optionally a phenol compound (U.S. Pat. No. 6,843,948); a phosphite compound, and optionally a phenolic compound (WO9905211), and a phosphoaryl compound (WO 0897684).
[0006] Sodium/potassium chloride or sodium/potassium chlorate have been used for persulfate-initiated polymerizations. (U.S. Pat. No. 3,728,303)
[0007] US 2004/0225095 and US 2004/0225096 describe the use of sodium acetate to prevent discoloration in PVDF due to residual persulfate radical initiator fragments (from potassium persulfate initiator).
[0008] U.S. Pat. No. 3,154,519 describes discoloration of PVDF exposed to high temperatures when stabilized with salts of surfactants having sulfonic acid ends. The problem was solved by the addition of barium and strontium salts. These salts are more costly and more toxic than the salts of the present invention.
[0009] Due to adverse environmental issues, the EPA has sought to eliminate the use of perfluorooctanoate surfactants currently used in the manufacture of many fluoropolymers. Perfluoroalkyl acids, such as perfluoroalkylsulfonic acid having six fully fluorinated alkyl groups, represent an alternative. The sulfonic acid may be used in the acid or salt form. The acid form has the advantage of being more soluble in water, making it more effective as a surfactant (allowing for lower use levels than the salt form), and also making it easier to wash out in a post-polymerization washing step. However, the residual acid surfactant leads to discoloration of the fluoropolymer during thermal processing.
[0010] U.S. Pat. No. 4,025,709 discloses the use of the sulfonic acid salts as surfactants for fluoropolymer synthesis. While the use of the salt form of the surfactant provides better thermal stability, higher usage levels are required when compared to the acid form, and the residual surfactant salt is more difficult to wash out of the fluoropolymer, having a negative effect on the fluoropolymer purity. The reference also exemplifies only the use of persulfate initiators. Persulfate initiator residuals also lead to discoloration of the fluoropolymer in thermal processing. WO 97/08214 describes the use of perfluoroalkyl acids, such as perfluoroalkylsulfonic acid having six fully fluorinated alkyl groups as a surfactant in fluoropolymer polymerization.
[0011] CN101513190 and Polymer (2006), 47(13), 4564-4570 describe the use of an additive containing a montmorillonite long chain alkyl quaternary ammonium salt (such as dodecyl, tri-methyl ammonium bromide) to improve mechanical properties.
[0012] High-purity fluoropolymer resins, especially of PVDF, are used by the semiconductor industry. While washing of a PVDF resin removes much of the residual surfactant having acid end groups, the residual surfactant is still high enough to cause color stability issues during thermal processing. The use of metal cations to provide heat stabilization is problematic in semiconductor applications, as a very low level of extractable metals, low TOC and low anions are required.
[0013] There is a need for a process to form thermally stable fluoropolymers using no persulfate initiators that lead to yellowing, to use an acid-containing surfactant in the acid form to reduce the levels of surfactant, to increase the purity of the fluoropolymer product compared to the salt-form of the surfactant, and to produce a product having a low TOC, a very low level of metal cations, and a very low level of anions.
[0014] Applicant has found that a fluoropolymer can be polymerized using a free-radical initiator and in the presence of an acid surfactant (such as a sulfonic acid surfactant), then treated with an ammonium salt, and especially a quaternary ammonium salt, to neutralize the residual surfactant acid, thus reducing or preventing yellowing and discoloration during thermal processing. The salts are not barium, strontium or hydroxide salts. A preferred fluoropolymer contains primarily vinylidene fluoride monomer units. A preferred salt is a quaternary ammonium halide or acetate, as it contains no added metals, making it especially useful in the electronics industry, and in high purity applications. In addition to being useful in semiconductor and electronics applications, the low TOC and metal cation-containing PVDF is also useful as a resin in many food and water applications, and can meet many regulatory requirements.
[0015] While not being bound to any particular theory, it is believed that the cations of the ammonium salt will react with residual acid groups from the surfactant to produce a surfactant salt. The resultant acid-surfactant salts are less reactive than the acid, and do not adversely affect the color of a melt processed product.
SUMMARY OF THE INVENTION
[0016] The invention relates to a heat stabilized fluoropolymer composition containing a fluoropolymer which is preferably a PVDF polymer or copolymer; from 0.001 to 600 ppm of residual acid end groups, and preferably from 100 to 400 ppm;
[0017] and from 1 to 30,000 ppm of one or more ammonium or phosphonium salts, other than a hydroxide, or one containing strontium or barium cations.
[0018] The invention also relates to a process for producing a thermally stable fluoropolymer comprising the steps of:
a) polymerizing one or more monomers comprising at least 50 mole percent of one or more fluoromonomers in the presence of an organic free-radical initiator and one or more surfactant(s) having acid end groups, to form a fluoropolymer; b) admixing from 1 to 30,000 ppm of one or more ammonium or phosphonium salts with said fluoropolymer to form a fluoropolymer composition, wherein said salt(s) is added at one or more points between the start of said polymerization and the heat processing of the fluoropolymer composition, wherein said salt is not a hydroxide, and does not contain strontium of barium cations.
[0021] The invention further relates to the thermally stable fluoropolymer product formed by the process, and the uses of the thermally stable fluoropolymer, especially in the area of electronics applications.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The invention relates to the stabilization of PVDF and other fluoropolymers by ammonium or phosphonium cations. The fluoropolymers are polymerized in the presence of surfactants containing acid end groups, such as sulfonic acid surfactants, and is preferably polymerized using an organic free radical initiator. The invention also relates to a stabilized fluoropolymer composition containing the fluoropolymer and residual acid-end-group surfactants neutralized by an ammonium salt.
[0023] The fluoropolymer of the invention is one formed primarily of fluoromonomers. The term “fluoromonomer” or the expression “fluorinated monomer” means a polymerizable alkene which contains at least one fluorine atom, fluoroalkyl group, or fluoroalkoxy group attached to the double bond of the alkene that undergoes polymerization. The term “fluoropolymer” means a polymer formed by the polymerization of at least one fluoromonomer, and it is inclusive of homopolymers, copolymers, terpolymers and higher polymers which are thermoplastic in their nature, meaning they are capable of being formed into useful pieces by flowing upon the application of heat, such as is done in molding and extrusion processes. The fluoropolymer preferably contains at least 50 mole percent of one or more fluoromonomers.
[0024] Fluoromonomers useful in the practice of the invention include, for example, vinylidene fluoride (VDF), tetrafluoroethylene (TFE), trifluoroethylene, chlorotrifluoroethylene (CTFE), hexafluoropropene (HFP), vinyl fluoride, hexafluoroisobutylene, perfluorobutylethylene (PFBE), pentafluoropropene, 3,3,3-trifluoro-1-propene, 2-trifluoromethyl-3,3,3-trifluoropropene a fluorinated vinyl ether, a fluorinated allyl ether, a non-fluorinated allyl ether, a fluorinated dioxole, and combinations thereof.
[0025] Especially preferred polymers are homopolymers of VDF, and copolymers made by the process of the invention are copolymers of VDF with HFP, TFE or CTFE, comprising from about 50 to about 99 weight percent VDF, more preferably from about 70 to about 99 weight percent VDF.
[0026] Especially preferred terpolymers are the terpolymer of VDF, HFP and TFE, and the terpolymer of VDF, trifluoroethene, and TFE. The especially preferred terpolymers have at least 10 weight percent VDF, and the other comonomers may be present in varying portions, but together they comprise up to 90 weight percent of the terpolymer.
[0027] Acrylic-modified PVDF, a hybrid polymer formed by polymerizing one or more acrylic monomers in the presence of a fluropolymer (preferably a PVDF) seed polymer, is also included in the invention.
[0028] The fluoropolymers of the invention can be made by means known in the art, such as by an emulsion, suspension, solution, or supercritical CO 2 polymerization process. Preferably the fluoropolymer is formed by an emulsion or suspension process.
[0029] The fluoropolymer is polymerized using a free-radical initiator. Especially useful initiators are the organic peroxide initiators. Among the organic peroxides which can be used for the polymerization are the classes of dialkyl peroxides, diacyl-peroxides, peroxyesters, and peroxydicarbonates. Exemplary of dialkyl peroxides is di-t-butyl peroxide, of peroxyesters are t-butyl peroxypivalate and t-amyl peroxypivalate, and of peroxydicarbonate, and di(n-propyl) peroxydicarbonate, diisopropyl peroxydicarbonate, di(sec-butyl) peroxydicarbonate, and di(2-ethylhexyl) peroxydicarbonate, diisopropyl peroxydicarbonate. The quantity of an initiator required for a polymerization is related to its activity and the temperature used for the polymerization. The total amount of initiator used is generally between 100 to 2000 ppm by weight on the total monomer weight used. Typically, sufficient initiator is added at the beginning to start the reaction and then additional initiator may be optionally added to maintain the polymerization at a convenient rate. Other free radical initiators may also be used, though some initiators, such as persulfate initiators, tend to discolor during thermal processing due to residual persulfate.
[0030] The fluoropolymers of the invention are polymerized in the presence of surfactants having acid end groups. The surfactant end groups during polymerization are preferably in the acid form, and are not neutralized. It is the residual acid end groups in the surfactant which are believed to lead to the discoloration of the fluoropolymer composition exposed to high heat. Examples of surfactant acid end groups would include, but not be limited to sulfonic acid, carboxylic acid, and phosphonic acid. In one embodiment, the surfactant is a fluorosurfactant having a chain length of C 4 to C 10 and could be an alkyl, ether or aryl group. This surfactant could be fully fluorinated (perfluoro-), partially fluorinated or non-fluorinated, as long as it contains the acid functionality. Combinations of surfactants are also envisioned, provided acid end groups are present on one or more of the surfactants.
[0031] Ammonium organic or inorganic salts are used to neutralize the surfactant acid end groups. Preferably the salts are water soluble and are not hydroxides. Water-soluble salts are preferred, since they can be added to the fluoropolymer as a water solution. This allows for easier handling and better dispersion, increasing the chance of reaction and allowing for a minimal usage of salt. By “water soluble” as used herein is meant that at least 3 grams, preferably at least 10 grams, and most preferably at least 20 grams of the salt will dissolve in 100 milliliters of water at 25° C.
[0032] Useful ammonium salts include, but are not limited to ammonium acetate, ammonium aluminum chloride, ammonium bromide, ammonium sulfate, ammonium aluminum sulfate, ammonium borates, ammonium stannate, ammonium carbamate, ammonium carbonate, ammonium chlorate, ammonium chloride, ammonium sulfamate, ammonium citrate, ammonium fluoride, ammonium fluorosulfonate, ammonium fluorosilicate, ammonium formate, ammonium hydroxide, ammonium lactate, ammonium laurate, ammonium magnesium carbonate, ammonium magnesium chloride, ammonium magnesium selenate, ammonium magnesium sulfate, ammonium malate, ammonium molybdate, ammonium nitrate, ammonium oleate, ammonium nitrite, ammonium oxalate, ammonium palmitate, ammonium phosphates, ammonium picrate, ammonium salicylate, ammonium sodium phosphate, ammonium stearate, ammonium succinate, ammonium sulfate, ammonium sulfides, ammonium tartrate, ammonium valerate, ammonium zinc sulfate, ammonium sulfamate, ammonium benzoate, ammonium nickel chloride, ammonium sulfites, ammonium propionate, ammonium phosphotungstate,
[0033] Preferred ammonium salts are the quaternary ammonium salts. Quaternary ammonium salts useful in the invention include, but are not limited to tetra-alkyl ammonium halides and tetra-alkyl ammonium acetate. The alkyl groups may be the same or different, and are preferably chosen from C 1-18 alkyl groups, preferably C 1-8 alkyl groups, and most preferably from C 1-4 alkyl groups—though alkyl-aryl and aryl quaternary ammonium compounds are also useful. Useful quaternary ammonium halides include, but are not limited to tetramethyl ammonium chloride, tetraethyl ammonium chloride, tetrapropyl ammonium chloride, and tetrabutyl ammonium chloride, tetramethyl ammonium bromide, tetraethyl ammonium bromide, tetrapropyl ammonium bromide, tetrabutyl ammonium bromide, tetrabutyl ammonium acetate, hexadecyltrimethyl ammonium bromide, tetramethyl ammonium fluoride, tetraethyl ammonium fluoride, tetrapropyl ammonium fluoride, and tetrabutyl ammonium fluoride, tetramethyl ammonium iodide, tetraethyl ammonium iodide, tetrapropyl ammonium iodide, and tetrabutyl ammonium iodide.
[0034] In another embodiment, phosphonium salts are used. Useful phosphonium salts include, but are not limited to Phosphonium acetate, phosphonium aluminum chloride, phosphonium bromide, phosphonium sulfate, phosphonium aluminum sulfate, phosphonium borates, phosphonium stannate, phosphonium carbamate, phosphonium carbonate, phosphonium chlorate, phosphonium chloride, phosphonium sulfamate, phosphonium citrate, phosphonium fluoride, phosphonium fluorosulfonate, phosphonium fluorosilicate, phosphonium formate, phosphonium hydroxide, phosphonium lactate, phosphonium laurate, phosphonium magnesium carbonate, phosphonium magnesium chloride, phosphonium magnesium selenate, phosphonium magnesium sulfate, phosphonium malate, phosphonium molybdate, phosphonium nitrate, phosphonium oleate, phosphonium nitrite, phosphonium oxalate, phosphonium palmitate, phosphonium phosphates, phosphonium picrate, phosphonium salicylate, phosphonium sodium phosphate, phosphonium stearate, phosphonium succinate, phosphonium sulfate, phosphonium sulfides, phosphonium tartrate, phosphonium valerate, phosphonium zinc sulfate, phosphonium sulfamate, phosphonium benzoate, phosphonium nickel chloride, phosphonium sulfites, phosphonium propionate, ammonium phosphotungstate,
[0035] Halide salts and acetate salts of the phosphonium or ammonium salts are preferred, with the chloride and bromide salts being most preferred. Salts of barium and strontium are not included in the invention.
[0036] When an acetate reacts with the acid group, the acetate forms a volatile species that can be removed during pellitization lowering contamination levels (measured as total organic compounds or TOC's).
[0037] The ammonium salts of the invention may be used in combination with metal cation salts—especially in applications where very low levels of residual metals are not a concern. Other metal salts include, but are not limited to sodium salts, calcium salts, potassium salts, zinc salts, and lithium salts. The quaternary ammonium salts, and especially the halides or acetate salts are useful in applications where the trace metals from the surfactant are undesired. Ammonium salts other than the quaternary ammonium salts are useful, but found to be less effective.
[0038] Blends of more than one type of salt is also contemplated by the invention. In one embodiment, a quaternary ammonium acetate or halide is combined with a small amount of a metal salt, such as sodium acetate or zinc oxide, and a synergistic effect is observed in terms of improvement of thermal stability and reduced coloring.
[0039] The level of salt useful in the invention is dependent on the amount of residual acid-containing surfactant in the fluoropolymer. Fluoropolymers that have been washed or otherwise treated and dewatered during or after the manufacturing process will require less salt, as they have lower levels of residual acid groups. Generally the level of salt needed is from 1 to 30,000 ppm, preferably from 1 to 5,000 ppm, preferably 3-1000 ppm, and most preferably for washed or treated samples with low levels of residual surfactant 3-100 ppm is used based on fluoropolymer solids. In one embodiment 100-420 ppm of sodium acetate trihydrate (60 to 250 ppm anhydrous) was found to be effective. In another embodiment, 1-100 ppm of tetraalkyl ammonium bromide is used on a washed or treated fluoropolymer having a lower level of residual surfactant. For other salts, a similar stoicheometric equivalent amount is useful (ie. for calcium acetate a level of 20 to 970 ppm would be useful).
[0040] The salts are combined with the fluoropolymer at any point during or after polymerization, and prior to processing at elevated temperatures. This includes, but is not limited to adding the salt into the reactor during polymerization or once polymerization has been completed; adding the salt into the polymer solution/suspension/emulsion just prior to drying (by means known in the art such as spray drying, or coagulation and drying); by adding the salt (preferably as a water solution spray) to the dried fluoropolymer at any point between drying and up to and including pelletization; etc., or by any combination thereof. Preferably the salt is added as an aqueous salt solution. One preferred method is to add the salt into the fluoropolymer solution/emulsion/dispersion just prior to drying—or as a separate stream simultaneously added as the fluoropolymer enters the drier. If the fluoropolymer is washed, the addition of the salt should occur after washing and before melt processing.
[0041] It can be advantageous to wash the fluoropolymer to remove some residual initiator, surfactant and other impurities, to provide a purer final product. In one embodiment, the fluoropolymer dispersion/solution/latex is washed, optionally after it is coagulated, to remove residuals and impurities and produce a higher purity product. The salt is then added after the washing step(s). Washing of the fluoropolymer should reduced the level of residual surfactant to below 500 ppm, preferably below 300 ppm, and more preferably below 200 ppm, based on the level of polymer solids.
[0042] It can also be advantageous to spray dry the fluoropolymer to remove additional residual initiator, surfactant and other impurities prior to the addition of the salt. The salt is then added during pelletization by either spraying a salt solution directly onto the fluoropolymer powder or by direct addition of a salt solution directly into the pelletization extruder.
[0043] The fluoropolymer composition of the invention may also include typical additives, including, but not limited to, dyes; colorants; impact modifiers; antioxidants; flame-retardants; ultraviolet stabilizers; flow aids; conductive additives such as metals, carbon black and carbon nanotubes; defoamers; crosslinkers; waxes; solvents; plasticizers; and anti-static agents. Other additives that provide whitening could also be added to the fluoropolymer composition, including, but not limited to metal oxide fillers, such as zinc oxide; and phosphate stabilizers.
[0044] The fluoropolymer composition of the invention can be melt-processed to form polymer structures by many different processes, such as extrusion, injection molding, fiber spinning, extrusion blow molding and blown film. The fluoropolymer composition resists discoloration at the elevated heat profiles in these processes.
[0045] It is also anticipated as part of the invention that addition of the salts to form a fluoropolymer composition could be applied to fluoropolymer coatings—especially those requiring high-temperature curing, to provide protection against discoloration.
[0046] The fluoropolymer composition of the invention could also be used to prevent or retard discoloration in other environments known to cause discoloration, such as exposure of the fluoropolymer to acids and oxidizing environments.
[0047] The heat stable fluoropolymer composition of the invention is especially useful in applications requiring high purity, low total organic compounds (TOC), low anions, a low metal content, and white color. Applications with these requirements include the semiconductor and electronics industries, as well as food, potable water and pharmaceutical uses.
[0048] As shown in the Examples, the addition of the salts of the invention to a PVDF polymer produced a composition having a very good heat resistance, as shown with a whiteness (as measured by YI) after heat-treatment of less than 40, less than 30, and even less than 20.
EXAMPLES
Example 1
Comparative
[0049] 60 grams of KYNAR 740 PVDF homopolymer resin polymerized in the presence of ZONYL 1033D (a perfluoroalkylsulfonic acid having six fully fluorinated alkyl groups, from DuPont) was blended with 1% solutions of the additives listed in Table 1 in a Brabender Plastometer under the following conditions:
[0050] Duration: 10 minutes
[0051] Sample Size: 60 grams of powder
[0052] Additive: 1% solutions of additive with water.
[0053] Method of mixing: weigh out sample and add the additive to the KYNAR 740 powder directly in a PE bag. Mix thoroughly.
[0054] Temperature: 205 C
[0055] Rotation Speed: 45 rpm
Sample Preparation
[0056] Remove melted polymer from the brabender bowl after mixing, press out sample for 1 minute @ 400 F, 10,000 psi, Cool press for 10 minutes in RT press @ 10,000 psi.
[0057] The YI values were measured by ASTM D1925 using a Minolta CR-300 Chroma meter.
[0058] The results from this experiment can be found in Table 1:.
[0000]
TABLE 1
Additive
Addi-
amount
Observa-
Measured
KYNAR Resin
tive
(ppm)
tion
YI
60 g PVDF lot 2008040
None
Na
Dark Yellow
32
60 g PVDF lot 2008040
NaAc
100
White
<10
60 g PVDF lot 2008040
NaAc
50
Off White
15-17
60 g PVDF lot 2008040
CaAc
100
White
<10
60 g PVDF lot 2008040
NaCl
100
White
<10
60 g PVDF lot 2008040
NH4Ac
100
Yellow
25-27
60 g PVDF lot 2008040
KAc
100
White
<10
60 g PVDF lot 2008040
ZnAc
100
White
<10
[0059] It was shown in this experiment that sodium, zinc, potassium and calcium were all effective, indicating that many metal cations may be useful. It was shown that both the organic NaAc (sodium acetate) as well as NaCl (sodium chloride) indicating that both organic and inorganic additives could be useful. It was also shown that the ammonium ion NH4 could be useful for color improvement, but not to the same level as observed with the additives having a metal cation.
Example 2
Comparative
[0060] 60 grams of KYNAR 740 PVDF homopolymer resin polymerized in the presence of ZONYL 1033D (a perfluoroalkylsulfonic acid having six fully fluorinated alkyl groups, from DuPont) was blended with various levels of a 1% calcium acetate solution in a Brabender Plastometer following conditions described in example 1. The results from this experiment can be found in Table 2.
[0000]
TABLE 2
Additive
Addi-
amount
Observa-
Measured
KYNAR Resin
tive
(ppm)
tion
YI
60 g PVDF homopolymer
None
0
Dark Yellow
38
60 g PVDF homopolymer
CaAc
50
Off White
24
60 g PVDF homopolymer
CaAc
100
White
8
60 g PVDF homopolymer
CaAc
200
White
14
60 g PVDF homopolymer
CaAc
300
Off White
22
60 g PVDF homopolymer
CaAc
400
Off White
28
Example 3
Comparative
[0061] 60 grams of KYNAR copolymer resin polymerized in the presence of ZONYL 1033D (a perfluoroalkylsulfonic acid having six fully fluorinated alkyl groups, from DuPont) was blended with various levels of a 1% sodium acetate solution in a Brabender Plastometer following conditions described in example 1. The results from this experiment can be found in Table 3.
[0000]
TABLE 3
Additive
Addi-
amount
Measured
KYNAR Resin
tive
(ppm)
YI
60 g PVDF copolymer
None
0
−1
60 g PVDF copolymer
NaAc
30
−17
60 g PVDF copolymer
NaAc
50
−12
60 g PVDF copolymer
NaAc
75
−12
60 g PVDF copolymer
NaAc
100
−10
60 g PVDF copolymer
NaAc
150
0
Example 4
[0062] 60 grams of KYNAR 740 PVDF homopolymer resin polymerized in the presence of ZONYL 1033D (a perfluoroalkylsulfonic acid having six fully fluorinated alkyl groups, from DuPont) was blended with various levels of a 1% tetrabutyl ammonium chloride (TBAC) solution in a Brabender Plastometer following conditions described in example 1. The results from this experiment can be found in Table 4.
[0000]
TABLE 4
Additive
Addi-
amount
Measured
KYNAR Resin
tive
(ppm)
YI
60 g PVDF homopolymer
None
0
44
60 g PVDF homopolymer
TBAC
50
40
60 g PVDF homopolymer
TBAC
100
29
60 g PVDF homopolymer
TBAC
175
14
60 g PVDF homopolymer
TBAC
200
12
60 g PVDF homopolymer
TBAC
225
7
60 g PVDF homopolymer
TBAC
250
18
60 g PVDF homopolymer
TBAC
300
45
Example 5
[0063] 60 grams of KYNAR copolymer resin polymerized in the presence of ZONYL 1033D (a perfluoroalkylsulfonic acid having six fully fluorinated alkyl groups, from DuPont) was blended with various levels of a 1% tetrabutyl ammonium chloride (TBAC) solution in a Brabender Plastometer following conditions described in example 1. The results from this experiment can be found in Table 5.
[0000]
TABLE 5
Additive
Addi-
amount
Measured
KYNAR Resin
tive
(ppm)
YI
60 g PVDF copolymer
None
0
2.69
60 g PVDF copolymer
TBAC
50
−2.99
60 g PVDF copolymer
TBAC
75
−8.49
60 g PVDF copolymer
TBAC
100
−11.5
60 g PVDF copolymer
TBAC
125
−15.53
60 g PVDF copolymer
TBAC
150
1.15
Example 6
[0064] 60 grams of KYNAR 740 PVDF homopolymer resin polymerized in the presence of ZONYL 1033D (a perfluoroalkylsulfonic acid having six fully fluorinated alkyl groups, from DuPont) was blended with various levels of a 1% tetraethyl ammonium chloride (TEAC) solution in a Brabender Plastometer following conditions described in example 1. The results from this experiment can be found in Table 6.
[0000]
TABLE 6
Additive
Addi-
amount
Measured
KYNAR Resin
tive
(ppm)
YI
60 g PVDF homopolymer
None
0
37
60 g PVDF homopolymer
TEAC
33
32
60 g PVDF homopolymer
TEAC
67
20
60 g PVDF homopolymer
TEAC
100
11
60 g PVDF homopolymer
TEAC
117
15
60 g PVDF homopolymer
TEAC
133
21
60 g PVDF homopolymer
TEAC
167
51
Example 7
[0065] 60 grams of KYNAR 740 PVDF homopolymer resin polymerized in the presence of ZONYL 1033D (a perfluoroalkylsulfonic acid having six fully fluorinated alkyl groups, from DuPont) was blended with various levels of either 1% tetrabutyl ammonium fluoride (TEAC) or a 1% tetrabutyl ammonium acetate (TBAAc) solution in a Brabender Plastometer following conditions described in example 1. The results from this experiment can be found in Table 7.
[0000]
TABLE 7
Additive
Addi-
amount
Observa-
Measured
KYNAR Resin
tive
(ppm)
tion
YI
60 g PVDF homopolymer
None
0
Yellow
41
60 g PVDF homopolymer
TBAF
50
Orange
>41
60 g PVDF homopolymer
TBAF
100
Orange
>41
60 g PVDF homopolymer
TBAF
150
Orange
>41
60 g PVDF homopolymer
TBAF
200
Orange
>41
60 g PVDF homopolymer
TBAAc
150
Off White
30
60 g PVDF homopolymer
TBAAc
200
Off White
30
60 g PVDF homopolymer
TBAAc
250
Brown
130
|
Fluoropolymers, specifically polyvinylidene fluoride (PVDF) polymers stabilized against color degradation due to high thermal exposure. The fluoropolymers are produced with free-radical initiators in the presence of surfactants containing acid end groups. The fluoropolymer resins are melt processed into final articles at high temperatures, above the melting point of the polymer. While the fluoropolymer is stable, residual acid surfactant causes discoloration during thermal processing. Stabilization is achieved by the addition of small amounts of ammonium or phosphonium cations to the fluoropolymer composition. It is believed the cations react with any residual acid to form a less reactive salt. These salts do not adversely affect the color of a melt processed product. The phosphonium or ammonium ions can be added to the fluoropolymer at any point from the polymerization step up to the thermal processing step. A preferred family of salts are quaternary alkyl ammonium halides.
| 2
|
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from provisional application Serial No. 60/295,195, filed on Jun. 1, 2001, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] U.S. Pat. No. 6,147,344, incorporated herein by reference, describes a system and method referred to as the Automated Ligand Identification System (ALIS) for screening proteins against libraries of small organic molecules for the discovery of small molecule ligands that bind to a target protein. ALIS allows each member of a library of potential ligands to be screened in parallel with every other member of that library. The protein is combined with the molecules, incubated, and provided to a high pressure liquid chromatography (HPLC) system. The resulting increased screening throughput is advantageous over approaches that require library members to be screened individually.
[0003] A current standard ALIS screening system utilizes sample volumes of 10 uL. These samples are prepared and held in standard 250 uL autosampler vials until they are ready to be loaded into the HPLC system. When ready, the samples are drawn out of the vials with a needle and injected into a sample loop mounted on a two-way valve. The valve is then turned to connect the sample to the HPLC.
SUMMARY OF THE INVENTION
[0004] The embodiment of the present invention reduces sample volumes of liquid biological materials, preferably to 100 nL, before being provided to an analytical system, such as an HPLC system. To prepare and hold such low volumes of liquid, a storage medium with microbores is used. Small quantities, such as 50 nL each, of library and protein are separately injected as droplets into openings in the storage medium to create the screening samples. The library and protein mix when the separate droplets are combined in the opening in the medium and are held by capillary forces. The mixed samples are incubated, e.g., for 30 minutes, at room temperature in a humidified chamber to prevent sample evaporation, and then loaded into the analytical system.
[0005] The medium is preferably a disk with a number of microbores arranged circumferentially near the edge of the disk. The disk rotates such that each microbore moves from a fill position where liquid is inserted, through one or more intermediate positions, to a load position where liquid is provided to the analytical system. The time it takes for a sample to go from the fill position to the load position is preferably set to be the incubation time.
[0006] The embodiment of the present invention preferably can provide reduced protein consumption because many proteins are obtained from biological sources and are available in minimal quantities. Therefore, it is desirable to minimize the quantity of protein required for each screen. The embodiment can also provide full integration and automation of all components, thereby combining separate processes into a single streamlined system designed to optimize the conditions for screening proteins against small molecule library mixtures.
[0007] Other features and advantages will become apparent from the following detailed description, drawings, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 shows a series of side views of a storage medium from an empty state to a mixed sample state.
[0009] [0009]FIG. 2 illustrates side views of a mixed sample as the sample is transferred from the medium.
[0010] [0010]FIG. 3 is a schematic of an automated in-line system illustrating loading and coupling a medium in stages.
[0011] [0011]FIG. 4 is a cross-sectional view of a storage medium and microbore with tubing as a variation of the coupling shown in FIG. 2.
DETAILED DESCRIPTION
[0012] Referring to FIG. 1, a storage medium 10 , such as a disk with microbores 12 , is loaded with a library of small molecules and protein, each in liquid form, preferably using low volume gas tight syringes. These liquids are held in the microbore with capillary forces. The syringes can be manipulated and loaded manually or by using automated stepping motors. Automation is preferable both for accuracy of sample volume and syringe positioning with respect to the storage medium. As shown in FIG. 1, the library and then protein (or vice versa) are introduced into microbore 12 to produce a mixed sample 14 .
[0013] Referring to FIG. 2, After an incubation time, the microbore storage medium is coupled to an HPLC system to load samples for screening in a manner described in the incorporated patent. The coupling from the storage medium to the HPLC system is preferably achieved by compressing HPLC liquid tubing 16 directly onto faces of the storage medium where microbore 12 are located. Compression pressure creates a seal between storage medium 10 and tubing 16 , allowing transfer of the samples into the HPLC system with minimal loss. Liquid sample 14 is pushed (or it could be pulled) from microbore 12 with pressure, such as by introducing a screen buffer to push the sample. This embodiment of the present invention thus allows the transfer of very small quantities to an analysis machine, such as an HPLC system, and in an automated manner.
[0014] Referring to FIG. 4, a storage medium 20 can have recessed portions 24 and 26 with a microbore 22 therebetween. Medium 20 is preferably made of a firm material that has some compressibility, such as PTFE, while tubing 30 used to move a sample out of microbore 20 is made of a material that is preferably more rigid than medium 30 . This relationship of the relative rigidity helps to create a tight seal between tubing 30 and medium 20 .
[0015] Referring to FIG. 3, system automation is achieved with an inline system in which samples are prepared and screened sequentially and continuously. Microbore holes are fabricated around a storage medium in the shape of the disk 36 and preferably located near the edge. The disk is rotated with a motor, such as with direct drive or a belt drive, from one position to the next for loading, incubating, and transferring the sample from the loading stage to an analytical system, such as the HPLC system. As shown in FIG. 3A, library and protein are loaded into disk 36 at position 1 . Disk 36 is rotated clockwise one step and library and protein are loaded at position 2 , while the sample at position 1 is incubating (FIG. 3B). With another step in the rotation of disk 36 , the incubated sample at position 1 is loaded via a coupling 38 into an HPLC or other analysis system while the sample in position 2 is incubated and a new sample is injected into disk 36 at position 3 (FIG. 3C). Operation in this manner results in a pipelined system for sample preparation, incubation, and screening.
[0016] While only a few microbores are shown, there would typically be many openings. The time from loading to coupling to the HPLC system is preferably set to be the desired incubation time. For example, if the disk has 32 openings, a sample would need to be moved sixteen times from loading to coupling to the HPLC system. Assuming a desired incubation time of about thirty-two minutes, each step would be designed to take two minutes so that the incubation is performed while the sample is moved. As indicated above, this means that the process can happen in an automated manner. While preferably done in a continuous inline manner, such continuous processing is not necessary and some or all portions of the processing could be done manually or the system could be stopped for some extended period of time as needed, such as for incubation. The system and process are said to be continuous in that the samples can be loaded and carried to the analysis system in a pipelined manner, and not that the storage medium is necessarily moving all the time.
[0017] The embodiment of the present invention has been described in terms of library and protein, but can include other biological samples of materials that need to be combined in quantities of about 100 nL or less. While the system is described in conjunction with an HPLC, other types of the analysis equipment can be used in which the sample is transferred from the medium to some other device for such analysis.
[0018] Having described embodiments of the present invention, it should be apparent that modifications can be made without departing from the scope of the invention as defined by the appended claims. For example, while the storage medium has been shown as a circular, rotatable disk, the medium could have other shapes and be rotated, such as an octagon shape or even a square shape, and rather than being rotated, the medium could be moved in a linear manner. While protein and ligands are described as the liquids, other biological samples could be introduced. While the storage medium has been described as moving to locations where samples are loaded and then transferred, the nozzles for inserting a sample and the tubing for extracting a sample could be movable with a stationary storage medium.
|
The storage medium stores multiple samples of liquid and is movable for providing those samples from a loading position to a position where the samples can be provided to an analysis system.
| 6
|
The U.S. Government has a paid-up license in this invention and the right in limited circumstances to require the patent owner to license others on reasonable terms as provided for by the terms of DAAAZI-90-C-0096 awarded by the Department of the Army.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a new and improved training projectile that has a predetermined range limited trajectory characteristic. More particularly, radially distributed flats induce the onset of gyroscopic instability at a predetermined range, thereby reducing the overall flight path of the projectile.
2. Description of the Art
U.S. Pat. No. 4,063,511 (Bullard) discloses a spinning shotgun projectile with grooves to streamline the projectile body thereby decreasing air resistance during flight.
U.S. Pat. No. 4,520,972 (Diesinger et al.) discloses a spin-stabilized training projectile, which changes its axial stability by operation of a stabilizer mounted at the rear end of the projectile.
U.S. Pat. No. 4,708,065 (Schilling et al.) discloses a training projectile with an annular recess around its circumference but does not use roll damping to truncate the normal trajectory of the projectile.
U.S. Pat. No. 4,905,602 (Buckland) discloses a spin-damped training projectile, which has an array of spin-damping fins mounted on the nose of the projectile.
Ranges for testing the trajectory of large caliber ammunition require a great deal of area for obvious safety reasons. A typical range for a 25-mm projectile has a length of approximately 14-km because projectiles of 25-mm typically travel a distance of 12-km. These distances change depending on the size of the projectile. The larger projectiles require a proportionally larger area. Many ordnance applications, i.e., target practice rounds, require projectiles to satisfy two conflicting objectives: 1) achieve a high performance flat trajectory to a specified range and 2) abruptly decelerate and thereby not exceed a specified range limit. Conventional spin stabilized projectiles, due to their pointed cylindrical shape, are severely limited in the degree to which they can satisfy these two conflicting requirements.
The problem is that high initial velocities result in excessively long carry ranges; or alternatively, if the specified range limitation is met, the initial trajectory performance is inadequate.
The present invention solves this problem by providing a training projectile with a roll damping augmentation section that causes the projectile to become gyroscopically unstable after a traveling a predetermined distance. The gyroscopically unstable trajectory causes the projectile to begin high yaw and thereby reduces the distance the projectile will ultimately travel.
SUMMARY OF THE INVENTION
This invention relates to a projectile that achieves a flat trajectory to a specified predetermined distance and upon reaching that distance abruptly becomes gyroscopically unstable. Accordingly, one embodiment is drawn to a projectile having an ogival nose portion; a posterior portion; and a midportion.
The midportion includes a longitudinally extending roll damping augmentation section disposed in a recess and extending outwardly no more than approximately the depth of the recess. The roll damping augmentation section has flats of flutes defining grooves which interact with oncoming air causing the projectile to become gyroscopically unstable at a predetermined range and continuously gyroscopically unstable thereafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the range limiting characteristics of a projectile with augmented roll damping in accordance with the invention.
FIG. 2 shows the range limited projectile having a substantially conical nose portion and a roll damping augmentation section having flutes.
FIG. 3 shows the range limited projectile having a substantially conical nose portion and a roll damping augmentation section having flats which define grooves.
FIG. 4 shows the range limited projectile having canted flutes.
FIG. 5 shows the range limited projectile having canted flats.
FIG. 6 shows an axial cross-section of the projectile having a canted role damping section.
FIG. 7 shows a longitudinal cross-section of the projectile at 90°.
FIG. 8 ( a ) and ( b ) shows variations in the number of flutes or flats respectively.
FIG. 9 shows the range limited projectile having adjustable canted roll damping flutes.
FIG. 10 shows a cross sectional view of the angle of orientation of the roll damping augmentation flutes or flats.
FIG. 11 shows an example of flute dimensions in a biconic configuration.
FIG. 12 shows an example of flute dimensions in a cone-cylinder configuration.
FIG. 13 shows the range limited projectile having a solid roll damping augmentation section.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to training rounds for which a range limitation mechanism has no substantial effect on the trajectory with a specified range, but acts to curtail the range thereafter, preventing the training rounds from exceeding the boundaries of the training area.
Typically, a rotating projectile has stable flight when the gyroscopic stability factor, which enables a projectile to have an aerodynamic stabilized flight trajectory, is greater than 1.0 and the dynamic stability factor, which represents the ability of a projectile to maintain a stable trajectory, is between zero and 2.0.
A rotating projectile has a stable flight trajectory when Sg>1 where: S g = I x 2 2 I y C m α πPd 3 ( ωd v ) 2
V is the velocity of the undisturbed oncoming air flow; Ix is the axial moment in inertia of the projectile; P is the air density; d is the reference diameter of the projectile; Iy is the transverse moment of inertia of the projectile; ω is the angular velocity about the longitudinal axis of the projectile and Cmα is the aerodynamic moment slope.
Standard International units may be used for consistency.
As d, Ix and Iy are fixed and P and Cmα only vary slightly for low angle, high velocity trajectories, the primary factor governing projectile stability is the ratio of angular velocity to forward velocity (ω/v).
The present invention seeks to achieve a range limited projectile through augmented roll damping which causes the spin rate to decay faster than the forward velocity. In the course of a normal trajectory, the velocity decay is greater than the spin rate decay thus the projectile becomes more stable. If the spin damping of the projectile is increased sufficiently for the spin rate decay to exceed the velocity decay, S g will decrease during flight and a projectile, which started off stable can have instability induced after travelling a critical distance. It is important that the roll damping mechanism does not increase the projectile drag, nor introduce extraneous pitching moment changes nor alter the Magnus moments in a manner that would adversely affect the capability of the training round to resemble as closely as possible a combat round that it is intended to simulate. The present training round design does not interfere with normal operation of full caliber projectiles on the use of subcaliber projectiles using sabots.
The instant invention enables a projectile to have a first segment of its trajectory gyroscopically stable and thus, correlate to a regular cartridge projectile. The flight characteristics of the first segment of the trajectory can be observed and recorded. The data gathered from observing the first segment of the trajectory may be used to extrapolate the trajectory the projectile would have if the roll damping augmentation feature were not present.
The first section of the trajectory has a flight velocity imparted from a muzzle with a Mach number. The firing also imparts an angular velocity proportional to the barrel rifling twist angle. As the projectile proceeds along its flight trajectory, the flight velocity begins to decrease at a faster rate than the angular velocity. This decrease necessitates the inventive augmented roll damping section as shown in FIGS. 2 and 3 to include flutes 120 or flats defining grooves 220 in the body of the projectile to enhance the moment forces around the rotational axis of the projectile and hence decrease the stability of the flight trajectory. Otherwise, the projectile will have a stable flight trajectory and such a trajectory will increase the distance the projectile will travel.
A second segment of the trajectory is gyroscopically unstable due to an increase in the rotational pitching moment caused by the interface of air and the augmented roll damping section of the projectile. The gyroscopic instability causes the projectile to assume high yaw angles. These high yaw angles provide high drag that decreases the distance the projectile will travel. One purpose of the recessed roll damping section 100 is to allow the design to be used in full caliber projectiles, fired from conventional gun barrels; or for the adaptation of existing sub-caliber projectile/sabot configurations without the need to modify the structurally critical subprojectile aft end/pusher base interface or the sabot manufacturing and/or molding process.
A rotating projectile used as a training round has a flight velocity (V) which drops more rapidly than the angular velocity (ω). Thus, as the projectile slows down, the flight pattern becomes more stable. The present invention, by the use of an augmented roll damping section in the midportion of the projectile, causes the projectile to experience a moment about its rotational axis which causes ( ω V ) 2
to decrease.
This causes the projectile to become gyroscopically unstable and to begin a high yaw and/or tumbling trajectory.
As shown in FIGS. 2 and 3, the augmented roll damping section 100 can have either flutes 120 or flats defining grooves 220 to interact with the air flow surrounding the projectile. The design of the roll damping feature, specifically the number of recessed flutes 120 or flats 220 , angle of the flutes 120 or flats 220 with respect to the longitudinal axis and how deep the flutes 120 or flats 220 are recessed into the body of the projectile, determines at what point in the trajectory path the projectile will become gyroscopically unstable and begin a high yaw flight trajectory. This point is known as the “crossover point” because the projectile is crossing over from a gyroscopically stable trajectory to a gyroscopically unstable trajectory. The crossover point is a function of spin rate, which is the speed the projectile is rotating (angular velocity) and decay rate, which is how braking forces are affecting a projectile's trajectory. By adjusting how rapidly the decay rate increases it is possible to predetermine the crossover point and use that determination to design a projectile with a desired crossover point.
The flutes 120 and flats 220 can have planar or twisted and/or curved surfaces thereby causing the air to have a greater or lesser effect on the trajectory of the projectile. The cumulative effect of a plurality of longitudinally elongated flutes 120 or flats 220 , deflecting air currents, causes the moment forces to overcome the tendency for the projectile to become more gyroscopically stable as it decelerates.
The flutes 120 or flats 220 are recessed in the midportion of the projectile 110 such that they do not extend substantially past the ogival surface of the projectile. The depth of the flutes 120 or flats 220 is approximately equal to the depth of the recess in the midportion and should be at least twice as high as the boundary layer momentum height so they do not become submerged in the boundary layer. The boundary layer is an area that surrounds a moving projectile and exerts forces on the projectile.
FIG. 2 and 3 show air flow along the surface of the projectile while in flight. The flutes 120 or flats 220 extend outwardly from the longitudinal axis 710 to overcome boundary layer effects and thus the flutes 120 or flats 220 will increase moment forces on the projectile 10 .
FIG. 2 shows the projectile 10 with a nose portion 20 which can be hollow and may be made of any resilient material such as aluminum or steel, a posterior portion 30 and a midportion 110 . The midportion 110 has a recessed roll damping augmentation section 100 which includes flutes 120 . FIG. 3 shows the projectile 10 with a conical nose portion 20 a posterior portion 30 and the roll damping augmentation section 100 includes flats 220 .
The flutes 120 and flats 220 may define air cavities 180 , which are filled with on-coming air. The air cavities 180 may be of virtually any depth, however, a depth of 2.5% to 7.5% of the projectile body diameter is preferred with 5.7% of the projectile body diameter being most preferred.
The flutes 120 are aligned along the longitudinal axis 710 of the projectile 10 as shown in FIG. 7 . The flutes 120 can be placed at varying degrees in relation to the axis and can vary in shape.
As shown in FIG. 10, roll damping section 100 may be angled in relation to the longitudinal axis 710 . The preferred angle of orientation, γ is 90° which maximizes the exposed surface area of the roll damping section 100 to oncoming air. As the angle of orientation of the flute or flat is decreased or increased from a 90° perpendicular angle, roll damping section 100 will have less surface area exposed to oncoming air flow because the roll damping section 100 will have more surface area closer to the body of the projectile. The angle or orientation γ also affects the shape of the air cavities 180 . The midportion roll damping section 100 increases the spin decay rate and deliberately drives the projectile 10 into gyroscopic instability at a predetermined range.
The roll damping augmentation section 100 which includes the flutes 120 or flats 220 is placed in the midsection 110 of the projectile 10 , which is near the center of gravity, thereby reducing undesired perturbations in the flight trajectory. The roll damping augmentation section can be the entire length of the projectile or up to 2.0 times the body diameter of the projectile. A preferred length is between 1 and 1.75 times the body diameter of the projectile. The most preferred length is 1.33 times the body diameter of the projectile.
The projectile 10 as shown in FIGS. 2 and 3 has an obturation band 160 to enable the muzzle to impart a spin on the projectile 10 as it is being discharged.
Through variations in the size, number and/or twist angles of the roll damping flutes 120 or flats 220 , the projectile's aerodynamic roll damping torques can be tuned to control the time of onset for the high drag condition, thereby providing vast improvements in tailoring the respective fast and slow portions of the trajectory. The deeper the flutes 120 or flats 220 into the midportion 110 , the sooner the projectile 10 will become gyroscopically unstable. The flutes 120 or flats 220 redirect the air flow around the surface of the projectile 10 because the flutes 120 and flats 220 cause the aerodynamic forces operating in opposite directions to produce a moment about the rotational axis, which decreases the gyroscopic stability and causes the projectile to being a high yaw and/or tumbling trajectory. As shown in FIGS. 8 ( a ) and ( b ), the roll damping section segments 100 can vary. Any number of segments would work. However, a preferred number of segments are between 4 and 12 equally spaced around the circumference of the projectile.
As shown in FIGS. 4 and 5, the roll damping augmentation section 110 may be canted at an angle β counter to the flow of air to increase the roll damping effect. Increasing the canted angle β of the flutes 120 or flats 220 relative to the longitudinal axis 710 , increases the angle at which the air interacts with the roll damping section 100 . This facilitates crossover to a gyroscopically unstable projectile trajectory, which causes the projectile to have a reduced trajectory. Values for β can be between zero and thirty degrees from the longitudinal axis. However, angles between 3 and 5 degrees are preferred. Angles of canting exceeding 15 degrees cause instability early in the flight trajectory.
As shown in FIG. 9, the roll damping augmentation flutes 120 , may also be adjusted by the user so that the angle of canting may be varied in the field. The angle of canting β at which the recessed flutes 120 are attached to the posterior portion 30 may be altered by having a plurality of connection slots 140 in the posterior portion 30 . Once the individual user selects a desired deflection angle of canting β, each of the flutes 120 can be affixed to a corresponding slot 140 of the posterior portion 30 .
FIG. 6 shows an axial cross-section of the midbody portion 110 when the roll damping section 100 is slightly canted. This depicts the relative depth of the roll damping section 100 . The roll damping section is sufficiently recessed to overcome boundary layer momentum forces.
FIG. 7 shows a longitudinal cross-section of the range limited projectile at 90°.
FIGS. 8 a and 8 b show that the range limited projectile can have various number of roll damping means.
FIG. 13 shows the roll damping section 100 may be solid. The flats 220 define grooves, which provide an interface with oncoming air thereby increasing the roll damping on the projectile 10 . This embodiment does not include an air cavity.
Example 1
FIG. 1 graphically illustrates comparative performance characteristics for a conventional spin stabilized projectile and a projectile with augmented roll damping. Reference line 12 shows the trajectory of a projectile without augmented roll damping. Reference line 14 shows the trajectory of the projectile of the instant invention with the augmented roll damping feature. The projectile without the range limiting feature (reference line 12 ) travels up to 12-km, whereas the projectile with the range limiting feature travels less than 8-km, a range reduction of 33%. This difference in maximum travel range can be important when considering the physical limitations of existing training and test ranges. The distance traveled by a projectile is a function of the mass of the projectile. The larger the mass, the greater the distance of its trajectory. However, the inventive roll damping augmentation will proportionally reduce the distance any projectile travels. Thus, the instant roll damping features will apply to any size projectile.
Example 2
FIGS. 11 and 12 show examples of dimensions of flutes 120 . The dimensions are expressed as a percentage of projectile body diameter and thus are applicable to any projectile. FIG. 11 shows a bi-conic projectile with flutes 120 having a depth from the surface of the projectile toward the longitudinal axis of 3.5% of the body diameter. FIG. 12 shows a cone-cylinder projectile where the flute depth is 5.7% of the body diameter for a cone-cylinder configuration. In both the bi-conic and cone-cylinder configurations, the length of the roll damping section is 133% of the body diameter.
The cone-cylinder groove height of 5.7% of the body diameter provided four times the roll damping of a bi-conic groove height of 3.5% of the body diameter.
A preferred embodiment of the invention utilizes recessed flutes 120 having a flat vertical surface extending outward from the longitudinal axis. This configuration increases the effective surface area of the flutes 120 . The flutes 120 have a length to height ratio of 15:1. A tungsten cylinder as the midportion 110 allows tailoring of gyroscopic stability to ensure cross-over and range truncation regardless of the ambient air temperature. The crossover rate will be unaffected in muzzle temperatures ranging from +150° C. to −60° C. when a tungsten cylinder is utilized. The flutes 120 or flats 220 may be molded into the tungsten cylinder or may be carved into the tungsten cylinder.
While preferred embodiments of the present invention have been illustrated in detail, it should be apparent that modifications and adaptations to those embodiments may occur to one skilled in the art without departing from the scope of the present invention as set forth in the following claims.
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A training projectile that utilizes flutes or flats to augment roll damping characteristics and thereby cause the projectile to crossover into a gyroscopically unstable trajectory pattern at a predetermined time. Prior to the crossover, the training projectile maintains a gyroscopically stable trajectory, which enables extrapolation to ascertain the trajectory of a non-training projectile that does not have an augmented roll damping section. The unstable trajectory pattern substantially reduces the distance the training projectile can traverse, thereby reducing the amount of area required for a training range.
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TECHNICAL FIELD
[0001] The present invention relates to; a method for controlling the flow volume of coal/kerosene slurry supplied into a decanter-type centrifugal separator in a solid-liquid separation process of using the decanter-type centrifugal separator; and an apparatus for producing upgraded brown coal.
BACKGROUND ART
[0002] A method of carrying out a solid-liquid separation process of using a decanter-type centrifugal separator, mechanically separating a solvent oil from dehydrated slurry, and thus obtaining cake has heretofore been known (refer to Patent Literature 1, for example).
[0003] Patent Literature 1, however, refers only to the point of separating a solid and a liquid (a cake and a solvent oil) by using a decanter-type centrifugal separator.
[0004] When dehydrated slurry (solid matter quantity) supplied to a decanter-type centrifugal separator increases (when the dehydrated slurry is coal/kerosene slurry, the case corresponds to the case where the flow volume itself is large and the case where the concentration of the contained coal is high), it sometimes happens that the dehydrated slurry gets clogged in the middle of a flow channel. Otherwise, it sometimes happens that the flow state of the dehydrated slurry deteriorates and a chattering phenomenon (mostly vibration and rattle of a rotary shaft) occurs. As a result, it sometimes happens that the load acting on the decanter-type centrifugal separator increases, damages component parts such as a gearbox and a bearing, and deteriorates solid-liquid separation performance.
CITATION LIST
Patent Literature
[0000]
Patent Literature 1: Japanese Unexamined Patent Application Publication No. 2010-116544
SUMMARY OF INVENTION
Technical Problem
[0006] An object of the present invention is to provide a method for controlling the flow volume of coal/kerosene slurry and an apparatus for producing upgraded brown coal, which are capable of preventing the flow state of the coal/kerosene slurry from deteriorating and exhibiting excellent solid-liquid separation performance while preventing the damage caused by overloading.
Solution to Problem
[0007] The present invention provides, as a means for solving the above problem, a method for controlling the flow volume of coal/kerosene slurry wherein, in a solid-liquid separation process of supplying dehydrated coal/kerosene slurry to a decanter-type centrifugal separator and separating the coal/kerosene slurry into a solid fraction and a liquid fraction: an opening degree target value is decided on the basis of the difference between a target value and an actually measured value of a torque acting on a screw conveyer of the decanter-type centrifugal separator; and the opening degree of a flow control valve, which is arranged in the middle of a supply line for supplying the coal/kerosene slurry into the decanter-type centrifugal separator, is adjusted to the opening degree target value.
[0008] By the method, it is possible to: control a flow volume directly so as not to incur overload on the basis of a torque acting on a screw conveyer; and prevent component parts from being damaged. Further, the flow volume of coal/kerosene slurry supplied into a decanter-type centrifugal separator does not increase more than necessary. As a result, the flow state of the coal/kerosene slurry does not deteriorate and it is possible to prevent solid-liquid separation performance from deteriorating.
[0009] Further, the present invention provides, as a means for solving the above problem, a method for controlling the flow volume of coal/kerosene slurry wherein, in a solid-liquid separation process of supplying dehydrated coal/kerosene slurry to a decanter-type centrifugal separator and separating the coal/kerosene slurry into a solid fraction and a liquid fraction: a target value of the electric current supplied to a motor to rotate and drive a screw conveyer of the decanter-type centrifugal separator is decided so that the liquid level in a tank of the coal/kerosene slurry supplied to the decanter-type centrifugal separator may take a constant value; an opening degree target value is decided on the basis of the difference between the electric current target value and an actually measured value of the electric current supplied to the motor; and the opening degree of a flow control valve, which is arranged in the middle of a supply line for supplying the coal/kerosene slurry into the decanter-type centrifugal separator, is adjusted to the opening degree target value.
[0010] By the method, it is possible to: control a flow volume indirectly so that the force acting on a screw conveyer may not become overload on the basis of a value of the electric current supplied to a motor to rotate and drive the screw conveyer; prevent component parts from being damaged; and prevent solid-liquid separation performance from deteriorating.
[0011] Further, the present invention provides, as a means for solving the above problem, a method for controlling the flow volume of coal/kerosene slurry wherein, in a solid-liquid separation process of supplying dehydrated coal/kerosene slurry to a decanter-type centrifugal separator and separating the coal/kerosene slurry into a solid fraction and a liquid fraction: a target value of the electric current supplied to a motor to rotate and drive a screw conveyer of the decanter-type centrifugal separator is decided so that the liquid level in a tank of the coal/kerosene slurry supplied to the decanter-type centrifugal separator may take a constant value; a first opening degree target value of a flow control valve, which is arranged in the middle of a supply line for supplying the coal/kerosene slurry into the decanter-type centrifugal separator, is decided on the basis of the electric current target value; a second opening degree target value of the flow control valve is decided on the basis of the difference between a target value and an actually measured value of a torque acting on the screw conveyer of the decanter-type centrifugal separator; and the smaller of the first opening degree target value and the second opening degree target value is used as the opening degree of the flow control valve.
[0012] By the method, since the opening degree of a flow regulating valve is controlled in consideration of the liquid level of coal/kerosene slurry in a tank and an electric current value of a motor to rotate and drive a screw conveyer, it is possible to more appropriately prevent: the force acting on the screw conveyer from becoming overload; component parts from being damaged; and solid-liquid separation performance from deteriorating.
[0013] Further, the present invention provides, as a means for solving the above problem, a method for controlling the flow volume of coal/kerosene slurry wherein, in a solid-liquid separation process of supplying dehydrated coal/kerosene slurry to a decanter-type centrifugal separator and separating the coal/kerosene slurry into a solid fraction and a liquid fraction: a target value of the electric current supplied to a motor to rotate and drive a screw conveyer of the decanter-type centrifugal separator is decided so that the liquid level in a tank of the coal/kerosene slurry supplied to the decanter-type centrifugal separator may take a constant value; a first opening degree target value of a flow control valve, which is arranged in the middle of a supply line for supplying the coal/kerosene slurry into the decanter-type centrifugal separator, is decided on the basis of the electric current target value; a second opening degree target value of the flow control valve is decided on the basis of the difference between a target value and an actually measured value of a torque acting on the screw conveyer of the decanter-type centrifugal separator; a flow volume of the coal/kerosene slurry in the supply line ranging from the tank to the decanter-type centrifugal separator is decided so that the liquid level in the tank of the coal/kerosene slurry supplied to the decanter-type centrifugal separator may take a constant value and a third opening degree target value of a flow regulating valve is decided on the basis of the difference between the decided slurry flow volume and an actually measured value; and the smallest of the first opening degree target value, the second opening degree target value, and the third opening degree target value is used as the opening degree of the flow control valve.
[0014] By the method, since the opening degree of a flow regulating valve is controlled in consideration of the flow volume of coal/kerosene slurry flowing in a supply line in addition to the liquid level of the coal/kerosene slurry in a tank and an electric current value of a motor to rotate and drive a screw conveyer, it is possible to yet more appropriately prevent: the force acting on the screw conveyer from becoming overload; component parts from being damaged; and solid-liquid separation performance from deteriorating.
[0015] It is desirable that the opening degree of a flow control valve increases and decreases at a predetermined cycle.
[0016] By the method, it is possible to appropriately prevent clogging of a supply line and defective flow by finely increasing and decreasing the flow volume of coal/kerosene slurry.
[0017] Further, the present invention provides, as a means for solving the above problem, an apparatus for producing upgraded brown coal including: a tank to retain coal/kerosene slurry; a decanter-type centrifugal separator having an outer rotary cylinder and a screw conveyer arranged relatively-rotatably in the outer rotary cylinder and driven by the drive of a motor; a supply line connecting the tank to the decanter-type centrifugal separator; a flow regulating valve being arranged in the supply line and regulating the flow volume of the coal/kerosene slurry; a torque detection sensor to detect a torque acting on the screw conveyer; and a control section that, in a solid-liquid separation process of using the decanter-type centrifugal separator, decides an opening degree target value on the basis of the difference between a target value of a torque acting on the screw conveyer and an actually measured value detected with the torque detection sensor and adjusts the opening degree of a flow control valve arranged in the middle of the supply line for supplying the coal/kerosene slurry into the decanter-type centrifugal separator to the opening degree target value.
[0018] Further, the present invention provides, as a means for solving the above problem, an apparatus for producing upgraded brown coal including: a tank to retain coal/kerosene slurry; a liquid level detection sensor for detecting the liquid level of the coal/kerosene slurry in the tank; a decanter-type centrifugal separator having an outer rotary cylinder and a screw conveyer arranged relatively-rotatably in the outer rotary cylinder and driven by the drive of a motor; a supply line connecting the tank to the decanter-type centrifugal separator; a flow regulating valve being arranged in the supply line and regulating the flow volume of the coal/kerosene slurry; and a control section that decides a target value of the electric current supplied to the motor to rotate and drive the screw conveyer of the decanter-type centrifugal separator so that the liquid level in the tank may take a constant value on the basis of a detected signal of the liquid level detection sensor, decides an opening degree target value on the basis of the difference between the electric current target value and an actually measured value of the electric current supplied to the motor, and adjusts the opening degree of a flow control valve arranged in the middle of the supply line for supplying the coal/kerosene slurry into the decanter-type centrifugal separator to the opening degree target value.
[0019] Further, the present invention provides, as a means for solving the above problem, an apparatus for producing upgraded brown coal including: a tank to retain coal/kerosene slurry; a liquid level detection sensor for detecting the liquid level of the coal/kerosene slurry in the tank; a decanter-type centrifugal separator having an outer rotary cylinder and a screw conveyer arranged relatively-rotatably in the outer rotary cylinder and driven by the drive of a motor; a supply line connecting the tank to the decanter-type centrifugal separator; a flow regulating valve being arranged in the supply line and regulating the flow volume of the coal/kerosene slurry; and a control section that decides a target value of the electric current supplied to the motor to rotate and drive the screw conveyer of the decanter-type centrifugal separator so that the liquid level in the tank may take a constant value on the basis of a detected signal of the liquid level detection sensor, decides a first opening degree target value of a flow control valve arranged in the middle of the supply line for supplying the coal/kerosene slurry into the decanter-type centrifugal separator on the basis of the electric current target value, decides a second opening degree target value of the flow control valve on the basis of the difference between a target value and an actually measured value of a torque acting on the screw conveyer of the decanter-type centrifugal separator, and uses the smaller of the first opening degree target value and the second opening degree target value as the opening degree of the flow control valve.
[0020] Further, the present invention provides, as a means for solving the above problem, an apparatus for producing upgraded brown coal including: a tank to retain coal/kerosene slurry; a liquid level detection sensor for detecting the liquid level of the coal/kerosene slurry in the tank; a decanter-type centrifugal separator having an outer rotary cylinder and a screw conveyer arranged relatively-rotatably in the outer rotary cylinder and driven by the drive of a motor; a supply line connecting the tank to the decanter-type centrifugal separator; a flow regulating valve being arranged in the supply line and regulating the flow volume of the coal/kerosene slurry; and a control section that decides a target value of the electric current supplied to the motor to rotate and drive the screw conveyer of the decanter-type centrifugal separator so that the liquid level in the tank may take a constant value on the basis of a detected signal of the liquid level detection sensor, decides a first opening degree target value of a flow control valve arranged in the middle of the supply line for supplying the coal/kerosene slurry into the decanter-type centrifugal separator on the basis of the electric current target value, decides a second opening degree target value of the flow control valve on the basis of the difference between a target value and an actually measured value of a torque acting on the screw conveyer of the decanter-type centrifugal separator, decides the flow volume of the coal/kerosene slurry in the supply line ranging from the tank to the decanter-type centrifugal separator so that the liquid level in the tank of the coal/kerosene slurry supplied to the decanter-type centrifugal separator may take a constant value, decides a third opening degree target value of the flow regulating value on the basis of the difference between a decided slurry flow volume and an actually measured value, and uses the smallest of the first opening degree target value, the second opening degree target value, and the third opening degree target value as the opening degree of the flow control valve.
[0021] It is desirable that a control section increases and decreases the opening degree of a flow control valve at a predetermined cycle.
Advantageous Effects of Invention
[0022] According to the present invention, since the flow volume of coal/kerosene slurry supplied to a decanter-type centrifugal separator is controlled, it is possible to effectively prevent: the decanter-type centrifugal separator from being overloaded and being mechanically damaged; or solid-liquid separation performance from deteriorating. As a result, it is possible to stabilize an upgraded brown coal process.
BRIEF DESCRIPTION OF DRAWINGS
[0023] FIG. 1 is a view showing the outline of an upgraded brown coal producing apparatus according to First Embodiment.
[0024] FIG. 2 is a view showing the outline of an upgraded brown coal producing apparatus according to Second Embodiment.
[0025] FIG. 3 is a view showing the outline of an upgraded brown coal producing apparatus according to Third Embodiment.
[0026] FIG. 4 is a view showing the outline of an upgraded brown coal producing apparatus according to Fourth Embodiment.
[0027] FIG. 5 is a graph showing the change of a flow volume in a supply line of an upgraded brown coal producing apparatus according to Fifth Embodiment.
DESCRIPTION OF EMBODIMENTS
[0028] Embodiments according to the present invention are explained hereunder in reference to the attached drawings.
First Embodiment
[0029] FIG. 1 shows the outline of an upgraded brown coal producing apparatus according to First Embodiment. The upgraded brown coal producing apparatus includes a tank 1 to retain coal/kerosene slurry and a decanter-type centrifugal separator 2 to separate the coal/kerosene slurry supplied from the tank 1 into a solid fraction and a liquid fraction.
[0030] The coal/kerosene slurry is supplied arbitrarily to the tank 1 . Usually the coal/kerosene slurry is supplied so that a liquid level in the tank 1 may be maintained at a nearly constant level. The liquid level of the coal/kerosene slurry in the tank 1 is detected by a liquid level detection sensor 3 .
[0031] A pump 5 , a first valve 6 , and a second valve 7 are connected in sequence from the side of the tank in the middle of a supply line 4 ranging from the tank 1 to the decanter-type centrifugal separator 2 . The role of the first valve 6 is to regulate the flow volume of the coal/kerosene slurry supplied into the decanter-type centrifugal separator 2 . The role of the second valve 7 is to increase and decrease the flow volume of the coal/kerosene slurry in a predetermined range in the supply line 4 (the detail will be explained in Fifth Embodiment that will be described later). Further, a reflux line 8 to connect a point between the pump 5 and the first valve 6 to the tank 1 is arranged.
[0032] The decanter-type centrifugal separator 2 is configured by arranging a cylindrical body 10 , which contains a screw conveyer (not shown in the figure), in a separator main body 9 . A rotary cylindrical section 12 to rotate by the drive of a motor 11 protrudes from an end section of the screw conveyer. The rotary cylindrical section 12 is supported rotatably by a support plate 13 arranged on the one end side of the separator main body 9 . Further, the rotary cylindrical section 12 is connected to the supply line 4 and the coal/kerosene slurry flows in the interior. A rotary shaft 14 protrudes from the other end section of the screw conveyer and is supported rotatably by a support plate 15 arranged on the other end side of the separator main body 9 . The rotary torque of the screw conveyer is detected by a torque meter 16 . The rotary torque detected by the torque meter 16 is converted into an electric signal (4 to 20 mA DC) by a transmitter 17 and transmitted to a regulator 18 . The regulator 18 outputs a control signal to the first valve 6 on the basis of the received detected value of the rotary torque and regulates the opening degree thereof. Although it is not shown in the figure, a solid substance discharge port for discharging a cake (solid substance) obtained by separating a solid from a liquid and a liquid substance discharge port for discharging a liquid substance are formed at the other end section of the separator main body 9 .
[0033] In an upgraded brown coal producing apparatus configured as stated above, coal/kerosene slurry is separated into a solid fraction and a liquid fraction as follows.
[0034] Firstly, on the basis of the relationship between the supply load condition of coal/kerosene slurry supplied to the decanter-type centrifugal separator 2 (the flow volume of coal/kerosene slurry, the concentration of a solid substance contained in the coal/kerosene slurry, or the like; the flow volume of the coal/kerosene slurry is used here) and a torque set value of the decanter-type centrifugal separator 2 , a torque target value (SV value: Set Variable) is set beforehand on the basis of an empirical value such as an experimental result.
[0035] Then it is also possible to: actually drive the decanter-type centrifugal separator 2 ; and fine-tune the torque target value (SV value) on the basis of the rotary torque detected by a torque detection sensor (torque detected value).
[0036] Successively, an operator inputs the torque target value (SV value) through a DCS (Distributed Control System) in accordance with the difference of the operation condition of the decanter-type centrifugal separator 2 and other conditions. Then feedback control (here, PID control) is applied on the basis of the deviation between the inputted torque target value (SV value) and a torque detected value (PV value: Pressure Variable) sent from the transmitter 17 and an obtained computation value (MV value: Manipulative Variable) is transmitted to the first valve 6 as a manipulation signal. As a result, the opening degree of the first valve 6 is changed in accordance with the manipulation signal and the flow volume is adjusted.
[0037] Concretely, the opening degree of the first valve 6 is decided in accordance with the following expression.
[0000]
M
V
=
100
P
B
×
{
e
(
t
)
×
1
Ti
×
∫
e
(
t
)
t
+
Td
×
e
(
t
)
t
}
[
Exp
.
1
]
[0000] Mv(t): Control output,
e(t): Control deviation (torque target value SV−torque detected value PV),
PB: Proportional band (%),
Ti: Integral time (min.), and
Td: Derivative time (min.)
(PB, Ti, and Td are regulation parameter of control deviation).
[0038] The coal/kerosene slurry is supplied from the tank 1 to the decanter-type centrifugal separator 2 by driving the pump 5 while the opening degree of the first valve 6 is regulated as stated above. In the decanter-type centrifugal separator 2 , the screw conveyer rotates by the drive of the motor 11 and the coal/kerosene slurry supplied into the rotary cylindrical section 12 is separated into a solid fraction and a liquid fraction. The separated solid substance and liquid substance are discharged from the solid substance discharge port and liquid substance discharge port, respectively.
[0039] According to First Embodiment, since the opening degree of the first valve 6 is regulated on the basis of the rotary torque (torque target value SV and torque detected value PV) of the screw conveyer, it is possible to: control the flow volume of the coal/kerosene slurry so as not to overload the decanter-type centrifugal separator 2 ; and prevent the solid-liquid separation performance from deteriorating.
Second Embodiment
[0040] FIG. 2 shows the outline of an upgraded brown coal producing apparatus according to Second Embodiment. The upgraded brown coal producing apparatus is different from an apparatus according to First Embodiment on the following point. Here, in the following explanations, a part corresponding to a configuration according to First Embodiment is represented by an identical code and the explanation thereof is omitted.
[0041] The torque meter 16 only detects a rotary torque acting on the screw conveyer and is not used for controlling the opening degree of the first valve 6 . Then the value of the electric current applied to the motor 11 to rotate the screw conveyer and the opening degree of the first valve 6 are controlled as follows on the basis of a detection signal of the liquid level detection sensor 3 to detect the liquid level of the coal/kerosene slurry in the tank 1 .
[0042] That is, cascade control is applied on the basis of the liquid level detected by the liquid level detection sensor 3 and the electric current value of the motor 11 and a set value (SV value) of the electric current applied to the motor 11 is decided so that the liquid level in the tank 1 may take a constant value. Then a computation value (MV value) is calculated in accordance with the expression [Exp.1] stated earlier on the basis of the deviation between the decided set value (SV value) and an actually measured value (PV value), which is detected by a torque detection sensor, of the rotary torque of the screw conveyer. Then the opening degree of the first valve 6 is controlled in accordance with the calculated computation value.
[0043] According to Second Embodiment, since the value of the electric current applied to the motor 11 to rotate the screw conveyer and the opening degree of the first valve 6 are controlled on the basis of the liquid level of the coal/kerosene slurry in the tank 1 , it is possible to: control the flow volume of the coal/kerosene slurry so as not to overload the decanter-type centrifugal separator 2 while the liquid level of the coal/kerosene slurry in the tank 1 is maintained at a constant level; and prevent the solid-liquid separation performance from deteriorating.
Third Embodiment
[0044] FIG. 3 shows the outline of an upgraded brown coal producing apparatus according to Third Embodiment. The upgraded brown coal producing apparatus is different from apparatuses according to First Embodiment and Second Embodiment on the following point. Here, in the following explanations, a part corresponding to a configuration according to First Embodiment or Second Embodiment is represented by an identical code and the explanation thereof is omitted.
[0045] In the same manner as First Embodiment, a first torque target value (SV1 value) is set on the basis of the relationship between the supply load condition of coal/kerosene slurry supplied to the decanter-type centrifugal separator 2 and a torque set value of the decanter-type centrifugal separator 2 . Then a first computation value (MV1 value), which is a first opening degree target value, is calculated in accordance with the [Exp.1] on the basis of the deviation between the first torque target value (SV1 value) that has been set and a first actually measured value (PV1 value), which is detected by the torque detection sensor, of the rotary torque of the screw conveyer.
[0046] Further, in the same manner as Second Embodiment, cascade control is applied on the basis of a liquid level detected by the liquid level detection sensor 3 and an electric current value of the motor 11 , and a second set value (SV2 value) of the electric current supplied to the motor 11 is decided so that the liquid level in the tank 1 may take a constant value. Then a second computation value (MV2 value) that is a second opening degree target value is calculated in accordance with the [Exp.1] on the basis of the deviation between the decided second set value (SV2 value) and a second actually measured value (PV2 value) of the electric current supplied to the motor 11 to rotate the screw conveyer.
[0047] Then the calculated first computation value (MV1 value) and second computation value (MV2 value) are compared (Low Select) and the opening degree of the first valve 6 is controlled on the basis of the smaller computation (electric current) value.
[0048] According to Third Embodiment, since the opening degree of the first valve 6 is regulated by the smaller of the first computation value (MV1 value) and the second computation value (MV2 value), rapid change of the opening degree does not occur. As a result, it is possible to appropriately separate the coal/kerosene slurry into a solid fraction and a liquid fraction while the coal/kerosene slurry is conveyed in a more stable state in comparison with First Embodiment and Second Embodiment.
Fourth Embodiment
[0049] FIG. 4 shows the outline of an upgraded brown coal producing apparatus according to Fourth Embodiment. The upgraded brown coal producing apparatus is different from an apparatus according to First Embodiment on the following point. Here, in the following explanations, a part corresponding to a configuration according to First Embodiment is represented by an identical code and the explanation thereof is omitted.
[0050] In the same manner as First Embodiment, a first torque target value (SV1 value) is set on the basis of the relationship between the supply load condition of coal/kerosene slurry supplied to the decanter-type centrifugal separator 2 and a torque set value of the decanter-type centrifugal separator 2 . Then a first computation value (MV1 value) that is a first target opening degree is calculated in accordance with the [Exp.1] on the basis of the deviation between the first torque target value (SV1 value) that has been set and a first actually measured value (PV1 value), which is detected by the torque detection sensor, of the rotary torque of the screw conveyer.
[0051] Further, in the same manner as Second Embodiment, cascade control is applied on the basis of a liquid level detected by the liquid level detection sensor 3 and an electric current value of the motor 11 , and a second set value (SV2 value) of the electric current supplied to the motor 11 is decided so that the liquid level in the tank 1 may take a constant value. Then a second computation value (MV2 value) that is a second target opening degree is calculated in accordance with the [Exp.1] on the basis of the deviation between the decided second set value (SV2 value) and a second actually measured value (PV2 value) of the electric current supplied to the motor 11 to rotate the screw conveyer.
[0052] Further, a slurry flow volume to be a target is decided so that the liquid level of the coke/kerosene slurry in the tank 1 may take a constant value. Furthermore, a slurry flow meter 19 is arranged in the supply line 4 and the flow volume of the coke/kerosene slurry flowing in the supply line 4 is detected. Then cascade control is applied on the basis of the deviation between the target value of the slurry flow volume and the detected value of the slurry flow volume detected by the slurry flow meter 19 and a third computation value (MV3 value) that is a third opening degree target value is calculated by the [Exp.1].
[0053] Successively, the opening degree of the first valve 6 is controlled on the basis of the smallest value of the calculated first computation value (MV1), second computation value (MV2), and third computation value (MV3).
[0054] According to Fourth Embodiment, since the opening degree of the first valve 6 is subjected to feedback control on the basis of the smallest value of the first computation value (MV1), the second computation value (MV2), and additionally the third computation value (MV3) of the first valve 6 calculated from the set value (SV3 value) and the actually measured value (PV3) of the slurry flow volume, it is possible to appropriately separate the coal/kerosene slurry into a solid fraction and a liquid fraction while the coal/kerosene slurry is conveyed in a still more stable state in comparison with Third Embodiment.
Fifth Embodiment
[0055] In an upgraded brown coal producing apparatus according to Fifth Embodiment, the following control capable of being adopted in any of the configurations according to First to Fourth Embodiments is applied.
[0056] That is, a tiny variation is given to the opening degree of the first valve 6 in the supply line 4 . Concretely, as shown in the graph of FIG. 5 , the opening degree of the first valve 6 is increased and decreased at a constant period (t) and so-called tact control is applied. As a result, it is possible to prevent the clogging of the supply line 4 , in particular the first valve 6 . Here, the period (t) and the amplitude of the increase and decrease (±X %: for example ±1%) may arbitrarily be set in response to the flow condition (the difference of the inner diameter of the supply line 4 and others) of the coal/kerosene slurry and can be set at appropriate values by experiment or the like. Further, when tact control is applied by the first valve 6 , it is also possible to apply flow control by changing the opening degree of the first valve 6 or by changing the opening degree of the second valve 7 .
[0057] According to Fifth Embodiment, it is possible to effectively prevent the clogging of the coal/kerosene slurry in the supply line 4 , in particular in the flow control valve by increasing and decreasing the flow volume of the coal/kerosene slurry in the supply line 4 in a certain range.
REFERENCE SIGNS LIST
[0000]
1 Tank
2 Decanter-type centrifugal separator
3 Liquid level detection sensor
4 Supply line
5 Pump
6 First valve (flow control valve)
7 Second valve
8 Reflux line
9 Separator main body
10 Cylindrical body
11 Motor
12 Rotary cylindrical section
13 Support plate
14 Rotary shaft
15 Support plate
16 Torque meter
17 Transmitter
18 Regulator
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A method and apparatus that deterioration of the flow state of a coal/kerosene slurry while preventing the damage caused by overloading to thereby achieve excellent solid-liquid separation performance. In a solid-liquid separation supplying a dehydrated coal/kerosene slurry to a decanter-type centrifugal separator to separate the coal/kerosene slurry into a solid fraction and a liquid fraction, an opening degree target value is determined on the basis of the difference between a target value and an actually measured value of a torque that acts on a screw conveyor of the decanter-type centrifugal separator, and the opening degree of a flow volume control valve, which is arranged in the middle of a supply line for supplying the coal/kerosene slurry into the decanter-type centrifugal separator, is adjusted to the opening degree target value.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to an improved method of manufacture of metal components. More specifically, the present invention relates to a method of manufacture where components are composed of or built in thin sheets or layers.
[0003] 2. Background Information
[0004] In the manufacture of heavy machinery, component parts are usually forged from a single piece of stock metal. That is, a single stock block is usually machined to the desired dimensions of a particular component. This process requires a tremendous amount of time and energy. For example, to form a radial cylindrical member of approximately six inch depth and eighteen inch diameter, having several radially aligned apertures, would take heavy machinery and hours to produce. After all, the radial shell would have to be initially forged and then each aperture cut through the entire depth of the component. Such practice is unduly burdensome on anyone forging components in this manner.
[0005] Applicant's invention provides a straightforward, yet novel, solution to the problems mentioned above. By way of machining several relatively thin pieces of metal to achieve desired dimensions, and then layering those pieces upon one another to form the final three dimensional component, a tremendous amount of time and energy is saved. Primarily, time and energy is saved as each thin piece may be “laser cut” and then layered upon each other. Although the end result may be the same, the energy required to achieve that result is dramatically reduced. By way of practical example, if the radial member referenced above were to be forged from a single piece—only a relatively small percentage of machinist (those having the largest, most expensive tools) would be able to accomplish the task. Such is the result as a tremendous amount of power is required to cut through the entire depth of the components. However, if the same radial member were made by cutting each relatively thin (i.e., one quarter inch) piece to have the appropriate diameter and radially aligned apertures and layering each piece upon the other, much cheaper equipment may be used. As such, the lamination process of the present invention can be accomplished by most machinists, equipped with a relatively inexpensive laser cutter or some equivalent thereof. Perhaps the novelty of the present invention lies in the fact that the sum of the energy required to cut each layered piece is much less than the energy required to cut the single, thick piece.
[0006] The method of the present invention may be performed by relatively small, inexpensive tools. As such, machine shops of even modest capability will be able to produce components they couldn't produce before. Components that were once expensive to produce will be now be made in a much cheaper fashion. The cost saving associated with the present method strongly speaks to the novelty of the method.
[0007] In view of the above, a great need exists for a process by which relatively large, complex metal components can be formed with inexpensive tools in a remarkably small period of time. Applicant's invention provides such a process. By way of lamination, thin pieces may be cut to appropriate dimension and then layered upon one another to form a single component. The time and energy saved in cutting several thin such pieces rather than a single, thick piece is tremendous.
SUMMARY OF THE INVENTION
[0008] The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a method of manufacturing metal components that provides an improvement both with respect to the time and energy typically required to produce such components.
[0009] In further view of such, it is an object of the present invention to provide an improved method of manufacture of metal components whereby simple and inexpensive tools can be used.
[0010] It is another object of the present invention to provide an improved method of manufacture of metal components whereby a laser cutter can be used.
[0011] It is another object of the present invention to provide an improved method of manufacture of metal components whereby relatively thin pieces of component material are used in place of a single piece.
[0012] It is another object of the present invention to provide an improved method of manufacture of metal components whereby relatively thin pieces of component material are layered upon one another to form a final component.
[0013] It is another object of the present invention to provide an improved method of manufacture of metal components that establishes a tremendous improvement in the time required to compete such.
[0014] It is another object of the present invention to provide an improved method of manufacture of metal components that establishes a tremendous improvement in the power required to compete such.
[0015] It is another object of the present invention to provide an improved method of manufacture of metal components where relatively thin pieces of component material are affixed to one another through some affixing process.
[0016] In view of the foregoing and other related objectives, Applicant's invention provides a method in which relatively thin pieces of component material are layered upon one another to form a single, laminated component. Using this method, individual pieces may be cut in any number of ways and placed in combination with other pieces to provide a single component. Combining relatively thin pieces, all of which may be configured in any number of ways, allows extremely complex component pieces to be formed. For many purposes laminated components perform as well as pieces forged from a single piece of stock metal.
[0017] The first step of the present method involves selecting a plurality of relatively thin, substantially planar, sheets of metallic material. This material may be comprised of a single metal, or some alloy thereof, depending on the desired properties of the final component pieces. In its most preferred form, these relatively thin, substantially planar, pieces are between one eighth of an inch and one inch in thickness.
[0018] Next, each planar sheet is cut according to some two dimensional reference, such as a flat template or equivalent thereof. As mentioned, these planar sheets are typically between one eighth of an inch to one inch in thickness. Accordingly, these sheets may be cut with smaller, less expensive tools. In its most preferred form, the present invention employs use of a laser cutter as known in the art. Use of a laser cutter is extremely fast and relatively accurate in the production of specifically cut pieces. Importantly, the layered pieces may be of varying widths—this allows a greater degree of precision in forming the final components.
[0019] After the sheets have been cut according to the desired dimensions, they are layered upon one another to form the final three dimensional component. Each layer may then be bonded or pressed together, sometimes under heat, to form a final laminated component. This lamination process, as described, provides a significant reduction in both production time and the energy required to make the final component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a perspective view of a product of the method of the present invention.
[0021] FIG. 2 is a flow chart diagram of the preferred embodiment of the method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] A description of the general method of the preferred embodiment of the present invention is given as follows. Referring to FIG. 1 and FIG. 2 , the method of the present invention commences at step 10 , where a plurality of substantially planar, relatively thin sheets of metallic material 100 are selected. Metallic Sheets 100 , in the preferred embodiment, may be comprised of single metal or some alloy thereof, depending on the desired characteristic of the final component piece. Further, in the preferred embodiment, sheets 100 are of thickness between one eight of and inch to one inch in thickness. Such a thickness is preferred as this allows each sheet 100 to be cut with relatively small, non expensive tools such as a laser cutter, and allows each sheet 100 to be thick enough to actually be useful. However, as will be apparent to those skilled in the art, narrower pieces may be preferred for particularly small or particularly detailed components; while thicker pieces may be preferred for particularly large or simple pieces. Summarily, each sheet 100 may be of varying widths—this allows a greater degree of precision in forming the final components.
[0023] At step 12 , each planar sheet 100 is cut according to some two dimensional reference, such as a flat template or equivalent thereof. As mentioned, each sheet 100 is cut using a tool such as a laser cutter. Laser cutters are preferred as they are relatively accurate, perform in a fast manner, are easy to operate, and are relatively energy efficient.
[0024] At step 14 , each planar sheet is layered upon the other to form the final, three dimensional component 102 . At step 14 , a significant advantage of the present method is realized. That is, the time and energy spent cutting and assembling each sheet 100 to form component 102 is significantly less than that spent to forge a single component piece of the exact dimension of assembled component 102 . This saving in respect to time and energy increases super-linearly as the thickness and complexity of assembled component 102 increases. As such, the present method is particularly more useful for relatively thick components.
[0025] At step 16 , each sheet 100 is pressed or bonded to adjacent sheets 100 . Step 16 may be performed using a heat mechanism or some adhesive. According to the desired operation of function of assembled component 102 , step 16 may be performed by inserting some fastening means through each sheet 100 . Such a fastening means may a combination of screws or pins as known in the art.
[0026] In the detailed description to follow a product of the method of the present invention is described. However, the product is not offered in a limiting sense, but rather is offered as one of several example products that may result from the method of the present invention. Other such products will certainly be apparent to those skilled in the art upon reference to this disclosure. For example, the method of the present invention is thought to be particularly useful in production of “A Device for Actuating a Reciprocating Recovery Means for Underground Fluid,” best described in a patent application filed on Oct. 12, 2004, having U.S. Express Mail # EV 298572059 US, a copy of which accompanies this application as appendix A.
[0027] Referring again to FIG. 1 and FIG. 2 , a radial component having a diameter of eighteen inches, a thickness of six inches, a central aperture having a six inch diameter, and a series of radially aligned apertures each having a diameter of one inch is shown. At step 10 , six, one inch, sheets 100 are selected. In this example each sheet is of a rectilinear dimension. At step 12 , each sheet 100 is cut, with a laser cutter, to have an eighteen inch diameter, a central aperture having a six diameter, and a series of radially aligned apertures having a diameter of one inch. At step 14 , all six sheets 100 are layered upon each other to so that the commination of the sheets forms an eighteen inch by six inch member, having the apertures as described above. Finally, at step 16 , sheets 100 are pressed on bonded togther using some heating means, adhesive means, or fastening means as known in the art.
[0028] Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention.
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An improved method of manufacture of metal components where a plurality of relatively thin, substantially planar sheets are selected and then cut using a laser cutter+or similar cutting means. The sheets are then layered upon one another and bonded or pressed together to form a final, laminated component.
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CLAIM FOR PRIORITY
[0001] This application claims priority to International Application No. PCT/EP01/14175 which was published in the German language on Jun. 12, 2003, and filed in the German language on Dec. 4, 2001, the contents of which are hereby incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The invention relates to a method for running communication services in a communication system and to a network device for implementing such a method.
BACKGROUND OF THE INVENTION
[0003] In communication systems, for example mobile radio networks according to the GSM (Global System for Mobile Communication) or UMTS (Universal Mobile Telecommunication System) standard, connections between two stations or network elements that are located at a distance from each other are generally set up via a plurality of further network elements, so that the two end stations can communicate with each other.
[0004] The session initiation protocol SIP is known for signaling connections (sessions) between in particular mobile users or stations and this describes a protocol and a network infrastructure. According to this, SIP messages are routed from a source user or a first station generally via a plurality of signaling servers to a second station as the destination user. In order to be able to provide extended communication services, such as for example session forwarding, number translation, pre-paid, etc. in such a signaling environment, different approaches are under discussion, such as call processing language CPL, SIP servlets (SIP-Java programming interface), SIP CGI (common gateway interface/general SIP access interface). A service thereby generally comprises a service logic in the form of a program code and status information in the form of data. In the case of personalized services, said status information is station-specific or user-specific. When forwarding messages, the signaling servers run the service logic or execute its instructions, whereby status information is included. In this way the service logic can influence the response of the signaling server.
[0005] In such an environment problems arise due to the possibilities for distributing the service logic and status information. If a new service is launched, this information must be made available to the signaling servers involved in the running process. An obvious approach would be to install said information in a permanent manner for administrative purposes on a specific signaling server. In the case of personalized services, this would however require a user or their station always to use the same signaling server. This assumption is not practical for the following reasons:
a) in mobile radio networks users or their stations are generally mobile and can only or have to use a signaling server in their proximity, located for example in a local intranet, in a dynamic manner. b) A signaling server may break down, whereupon the user or their station must be able to use an alternative server. The information would also have to be installed on such a server to be made additionally available. c) A load distribution method can generally be used in mobile radio networks, to assign users or their stations to the signaling server with the smallest load out of a plurality of signaling servers.
[0009] This possibility would also not be applicable or would require the information to be installed on the plurality of signaling servers.
[0010] These problems occur in particular in systems, as for example with the multimedia subsystem architecture defined by 3GPP (3 rd Generation Partnership Project), according to which a signaling server from a plurality of available signaling servers is allocated to a user-side station in a dynamic manner during the registration process.
[0011] IETF proposals from the internet field (IETF: Internet Engineering Task Force), such as Java Enhanced SIP (JES) and servlet delivery (SDLI), describe methods, by means of which service logic and status information can be transported together with signaling messages. Stations or terminals “append” the service logic to messages, whereby the signaling servers extract said information and run the service logic as required. However such approaches do not resolve the above problem satisfactorily:
d) In a mobile network environment the bandwidth of the air interface is a valuable resource. It would be a waste of this resource, if a large amount of service logic and status information were transmitted from the stations into the network. e) For security reasons many network operators also have serious misgivings about receiving and running just any service logic from user-side stations. This could have an adverse effect on the stability of the network. f) Also status information changes, which may result from the running of a service, cannot be stored permanently. This would be necessary however, if this changed status information were required for the repeat running of a service. g) It should be possible to run many services without involving an end station, e.g. call forwarding when the station is not available.
SUMMARY OF THE INVENTION
[0016] The invention discloses a method for providing communication services in a communication system with a view to distributing service logic and status information on signaling servers and to propose a network device for implementing such a method.
[0017] Advantageously, a service logic, in other words an executable program code, is stored in a network-side storage device, which network-side stations can access, when a station logs on or registers that a connection is to be set up for or to such a station or data is to be forwarded for such a station. The term connection of course not only covers a finally set-up communication connection but also simple signaling with control instructions, information data transmissions, etc.
[0018] Status information relating to such stations is preferably stored in the service database together with the service logic, so that this can also be called. When the service logic or information has changed, it should be possible to update the service logic and/or status information in the service database from the device running the service logic.
[0019] In mobile radio networks, mobile users or their stations are no longer mandatorily assigned to a specific signaling server in proximity to them. If a signaling server breaks down, the user and their station can simply use an alternative server. Instead of having to provide all the data on a plurality of alternative servers, it is adequate to provide a few replacement servers or databases in the network, which either receive the data by means of mirroring technology or from the actual database in the event of a breakdown. In principle transmission, as already known per se, from the station to the access device and via that to the service database is also possible.
[0020] A load distribution method can also be used in communication networks, to assign users or their stations in each instance to the signaling server with the smallest load out of a plurality of signaling servers.
[0021] The air interface is advantageously not loaded with a plurality of service logic data. Transmission can be reduced to a minimum or no transmissions at all.
[0022] Network operators can also block receipt of any service logic from user-side stations or only permit it via a reliably verifiable registration path. This would offer the network operator a higher level of security but means a reduction in flexibility from the point of view of the user due to the need for prior registration of a new service logic.
[0023] Status information changes, which result from the running of a service, can also be stored permanently in this way, which ultimately relieves the load on the network further, as the number of transmissions can be reduced for example on the air interface between user station and network.
BREIF DESCRIPTION OF THE DRAWINGS
[0024] An exemplary embodiment is described in more detail below with reference to the drawing, in which:
[0025] FIG. 1 shows an arrangement of network devices in a schematic communication system with method stages outlined therein for implementing a preferred method for distributing service logic and status information on signaling servers.
DETAILED DESCRIPTION OF THE INVENTION
[0026] FIG. 1 shows an outline of a communication system UMTS, which is preferably controlled on the basis of what is known as the Session Initiation Protocol (SIP). Only the network elements and network devices of relevance to the method described below are primarily shown.
[0027] With the exemplary embodiment described below, a communication connection is to be set up between a first user-side station A and a second user-side station B, to allow communication between these via the communication network UMTS. The two user-side stations A, B can be any data terminals, which advantageously support the SIP or a comparable protocol. In particular they can be cable-based or radio-based computers and telephones. It is also possible for one of these stations to be configured as a server for the passive delivery of requested data in the event of a corresponding request by the other station.
[0028] In order to set up a communication connection between one of the two stations A, B and the communication network, for example according to UMTS, what are known as SIP proxies PA or PB are provided in the area of the access network of the communication network. A station A, B, which is connected to the communication network UMTS, in other words is connected in particular to the corresponding SIP proxy PA or PB, in the SIP example sends what is known as a register message REGISTER for its registration at a first time t 1 to the access device PA or PB.
[0029] As shown in FIG. 1 , a service database DD is also provided in the communication network UMTS. One or a plurality of data logics and status information relating to a plurality of user-side stations A and B registered there are stored respectively in this database DD. After registration t 1 of a station A or B with the corresponding access device PA or PB, at a second time t 2 the corresponding access device PA or PB sends a request GET for transmission of the data relating to this correspondingly newly registered station A or B to the service database DD. After receipt of the request GET the service database DD sends service logic and/or status information to the requesting access device PA or PB. The access device PA or PB, which is preferably configured as a signaling server, thereby obtains the necessary service logic and/or the corresponding status information via a data path that preserves system resources. If the access device PA or PB is then to forward signaling messages from or to the station A or B, it can access the corresponding service logic and the corresponding status information for this station A or B and run the service logic or execute the instructions specified therein. In particular the status information can be accessed according to the service logic instructions, in order to modify it.
[0030] Advantageously, directly after an instruction to change service logic and/or status information, a corresponding update instruction can be transmitted from the access device PA or PB to the service database DD, as outlined with reference to the HTTP PUT instructions at a ninth time t 9 . Such updating of the data in the service database DD can of course also be implemented with a time delay or in particular when canceling the assignment of the station A, B to the corresponding access device PA or PB. The instruction to change the service logic and/or the status information in the area of the access device PA or PB can originate both from the assigned station A or B and from an independent further station, device or entity.
[0031] The service database DD can be configured both as a component of the communication network UMTS and as an external device. In particular it is also possible to equip the service database DD or another network device, for example a SIP proxy, with functions, which execute a corresponding functionality instead of the station A or B. This is advantageous, if for example a first station A, in respect of which data is to be changed, or a second station B, to which messages for example are to be sent, is not connected to the network or is not available for some other reason.
[0032] For example a request INVITE to set up a communication connection to the second station B could be sent out from the first station A after registration with a first access device PA, whereby the second station B for example is either not connected to the network or has stored a general instruction to forward information to another network device or network address in the access device PB assigned to it and/or the service database DD. In such a case, in the event of a request by the second station B, the service logic would reroute the request from a particular proxy or a correspondingly extended database by changing the address data correspondingly based on current status information. In the event that the second station B is itself not connected to the network, the corresponding function would be implemented in the service database DD or a correspondingly provided access device or other network device.
[0033] A simple exemplary embodiment of an advantageous method for distributed running of personalized communication services is described below with reference to FIG. 1 . The network topology shown with two users A, B, their respective signaling servers or access devices PA or PB and the database DD is used as the basis for this. The assignment of the two stations A, B to the corresponding access devices, in this case signaling servers PA or PB, is to be effected here by means of the SIP register message REGISTER as known per se. The interface between the access devices and the service database DD is to be an interface, which is for example based on the Hypertext Transfer Protocol HTTP (RFC 2616). Cancellation of the assignment of a station A, B to the assigned signaling server or the assigned access device PA or PB is to be effected correspondingly by a SIP-De-REGISTER message.
[0034] On connection to the communication network UMTS, stations A, B respectively send a REGISTER message at a first time t 1 to the corresponding access device PA or PB. The addresses of the corresponding access devices or SIP proxies PA or PB can be defined beforehand for the stations A or B via standard mechanisms, e.g. via what is known as multicast or according to DCHP (Dynamic Host Configuration Protocol), a standard dynamic station configuration protocol.
[0035] At a subsequent time t 2 the corresponding access devices PA or PB use an HTTP GET request to request the service logic and status information relating to the corresponding registered station A or B from the service database DD and receive this.
[0036] At a later, third time t 3 the first station A sends a request for a connection to be set up to the second station B by means of a SIP-INVITE message to the access device PA assigned to it. The access station PA assigned to it then runs the corresponding service logic at a fourth time t 4 . The request to set up a connection INVITE is then forwarded from the first access device PA at a fifth time t 5 to the second access device PB.
[0037] At a sixth time t 6 the second access device PB then runs the service logic, which is assigned to the second station B. Then at a seventh time t 7 the connection request INVITE is forwarded from the second access device PB to the second station B. The connection between the stations A and B is thereby set up, with the service logic instructions assigned to the stations being taken into account in each instance, said instructions being transmitted beforehand when they registered, from the service database DD to the corresponding access devices PA or PB.
[0038] When one of the stations A, B wishes to be removed from the communication network UMTS or to terminate the connection, it sends a De-REGISTRATION message De-REGIST. At this later time t 8 to the assigned access device PA or PB. The corresponding access devices PA or PB use an HTTP PUT instruction to write the status information modified during the previous fourth or sixth times t 4 , t 6 back to the database DD, so that this is available to be called in updated form for future runs.
[0039] According to alternative embodiments an update of the corresponding data in the service database DD can also be initialized directly by a station A or B, by said station transmitting corresponding instructions via the access devices PA or PB when it first registers in the communication network or at a later time. Updates can of course also be undertaken by another device or entity in the communication network with corresponding authorization.
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The invention relates to a method for running communication services or a corresponding service logic in a communication system (UMTS), whereby a station (A, B) logs on to an access device (PA or PB) of the communication system (UMTS), and service-related instructions depending on a service logic relating to the station (A or B) are emitted on the network side, in a network device on the connection path between the station (A, B) and another station (B or A). The aim of the invention is to enable the service logic to be updated without having to transmit it from the station with, for example, registration data each time. To this end, the service logic relating to said station (A or B) is called by the device (PA or PB) emitting the instruction, from a service data bank (DD) in which the service logic is stored on the network side.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority to U.S. provisional application Serial No. 60/432,421 filed Dec. 11, 2002 and entitled “Latch Assembly for Damper.”
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to damper assemblies, and in particular, relates to a latch usable in combination with a damper that, when installed within the ductwork of a building, strengthens the seal provided by the damper blades when the damper is closed.
[0003] Building and fire codes require that dampers be placed in specified heating, ventilation, and air conditioning ducts. Dampers include a pair of damper blades that operate in a normally open position, which allows air to flow through the ductwork. The blades can close to prevent air flow through the ductwork in response to a predetermined stimulus. The stimulus can be a dramatic increase in temperature, indicating a fire or other hazardous condition, or any other event that causes the damper blades to close.
[0004] Conventional damper blades are biased towards their closed position by a spring member or the like, but held open by a fusible link or other suitable member that prevents the blades from closing under the spring force. When the fusible link fails in a predetermined manner in response to an elevation in temperature, the mechanical interference maintaining the blades in their open position is removed, and the damper closes to form a seal with the duct with respect to airflow. As a result, airflow throughout the building is minimized in response to a fire or other hazardous condition.
[0005] It should be appreciated that the ability for the damper to prevent the hazardous material or fire from spreading throughout the building depends largely on the strength of the seal between the damper blades and the ductwork when the blades are closed. A damper becomes “fire-rated” by Underwriters Laboratories if it is able to withstand the extreme temperatures for a predetermined amount of time without weakening its seal between the blades and the duct. In conventional dampers, prolonged exposure to extreme temperatures associated with heat tend to weaken the damper components and the resulting seal.
[0006] What is therefore needed is a damper assembly capable of providing an enhanced seal between the damper blades and the duct with respect to conventional damper assemblies.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention recognizes that conventional dampers can be modified to increase their strength characteristics when closed, thereby reducing the risk of spreading fire or contaminants throughout a building during a hazardous situation.
[0008] In accordance with one aspect of the invention, a damper assembly is installed in a housing of the type having a pair of side walls connected to a pair of end wells that define a conduit extending therethrough. The damper assembly is movable from an open position to a closed position to control fluid flow through the conduit. The damper assembly includes at least one damper blade operating in a normally open position.
[0009] In accordance with another aspect of the invention, a biasing member applies a force to the damper blade biasing the blade towards the closed position. In one form, the biasing member is a spring member operably connected between the blade and the housing.
[0010] In accordance with still another aspect of the invention, a retaining member is in removable mechanical communication with the damper blade to maintain the damper blade in the open position against the biasing force.
[0011] In accordance with still another aspect of the invention, a latch mechanism is provided that engages to resist counter-movement of the damper blade towards the open position once the damper blade has closed. In one form, the latch mechanism includes a latch member and a corresponding catch member, one of which in mechanical communication with the blade, the other of which in mechanical communication with the housing, wherein an interference is created between latch member and catch member to resist counter-movement of the damper blade towards the open position once the damper blade has closed.
[0012] These and other aspects of the invention are not intended to define the scope of the invention for which purpose claims are provided. In the following 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 limitation, a preferred embodiment of the invention. Such embodiment also does not define the scope of the invention and reference must therefore be made to the claims for this purpose.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Reference is hereby made to the following drawings in which like reference numerals correspond to like elements throughout, and in which:
[0014] [0014]FIG. 1 is a perspective view of a damper assembly constructed in accordance with the preferred embodiment of the invention;
[0015] [0015]FIG. 2 is a perspective view of the damper blades of the damper assembly illustrated in FIG. 1;
[0016] [0016]FIG. 3 is a sectional side elevation view of the lower damper blade illustrated in FIG. 2;
[0017] [0017]FIG. 4 is a sectional side elevation view of the damper assembly illustrated in FIG. 1 with the blades in an open position;
[0018] [0018]FIG. 5 is a sectional side elevation view of the damper assembly illustrated in FIG. 4 but with the damper blades in a partially closed position;
[0019] [0019]FIG. 6 is a sectional side elevation view of the damper assembly illustrated in FIG. 5 but with the damper blades in a further closed position;
[0020] [0020]FIG. 7 is a sectional side elevation view of the damper assembly illustrated in FIG. 6 but with the damper blades in a fully closed position; and
[0021] [0021]FIG. 8 is a sectional side elevation view of the damper assembly similar to that illustrated in FIG. 4, but having a coupling assembly constructed in accordance with an alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0022] Referring initially to FIG. 1, a damper assembly 20 is installed in a rectangular housing 22 . It should be appreciated that housing 22 can be installed in the ductwork of a building or, alternatively, that housing 22 could be integral with the ductwork. The term “housing” is thus used broadly throughout this description to define a member that supports the damper assembly 20 in the ductwork of a building, regardless of whether the housing is a separate member and fit inside the ductwork, or whether the housing is integral with the ductwork. Unless otherwise stated, the components of damper assembly 20 are preferably formed of steel, though other suitable materials could be used.
[0023] Housing 22 is defined by opposing side walls 23 and 24 that are elongated in the direction of vertical axis V-V and are connected at their upper and lower ends to opposing end walls 26 and 28 , respectively. End wall 26 thus defines the upper end of damper assembly 20 while end wall 28 defines the lower end, such that end wall 26 is said to be disposed “above” end wall 28 . Walls 23 , 24 , 26 , and 28 define an internal void 50 that enables air to flow through the housing 22 (and ductwork of a building) along the direction of Arrow A.
[0024] The terms “upstream” and “downstream” are used herein with respect to the direction of airflow through the housing 22 along the direction of Arrow A. The term “longitudinal” is used throughout the description below to define a horizontal direction along axis L-L and parallel to the direction of air flow through damper assembly 20 . The term “transverse” is used to define a horizontal direction along axis T-T that is orthogonal to longitudinal axis L-L and vertical axis V-V.
[0025] Side walls 23 and 24 are connected to upper end wall 26 and lower end wall 28 at corresponding longitudinally extending upper and lower edges 34 and 36 , respectively. Edges 34 and 36 define the transverse boundaries of upper and lower walls 26 and 28 , respectively, and further define the vertical boundaries of side walls 23 and 24 . The longitudinal boundaries of end walls 26 and 28 are defined by transversely extending edges 30 and 32 . The longitudinal boundaries of side walls 23 and 24 are defined by edges 25 and 27 . Edge 25 defines the leading edge of the damper assembly 20 with respect to airflow, and is disposed upstream of edge 27 .
[0026] A pair of vertically elongated flanges 42 and 44 extends slightly transversely outwardly from edges 25 and 27 , respectively, of side wall 23 . A corresponding pair of flanges 46 and 48 extend slightly transversely outwardly from edges 25 and 27 , respectively, of side wall 24 . Flanges 42 and 46 are disposed upstream of flanges 44 and 48 . Flanges 42 , 44 , 46 , and 48 extend vertically a distance slightly beyond edges 34 and 36 and are connected at their outer ends to a pair of upper and lower flanges 52 and 54 , respectively, that extend vertically outwardly from edges 30 and 32 , respectively. A corresponding pair of upper and lower flanges 38 and 40 , respectively, extends longitudinally outwardly from flanges 52 and 54 , respectively, and is configured to be mounted to the interior of the ductwork of a building (not shown). Transverse flanges 42 , 44 , 46 , and 48 , and vertical flanges 38 and 40 are configured to form a seal against the inner periphery of the ductwork, f
[0027] Referring also to FIG. 2, upper and lower damper blades 56 and 58 , respectively, are disposed within void 50 and extend between the inner surfaces of side walls 23 and 24 . Blades 56 and 58 extend horizontally when the damper assembly 20 is in the open position illustrated in claim 1 to enable air to flow through the damper assembly and circulate throughout the building. Blades 56 and 58 present upper surfaces 57 and 59 , respectively, and lower surfaces 61 and 63 , respectively, it being appreciated that the terms “upper” and “lower” are used herein to describe the blades when they are in the open position. Blades 56 and 58 define leading edges 60 that are disposed upstream of trailing edges 62 when the blades are open. Blades 56 and 58 have a longitudinal thickness that is sufficient to seal the void 50 with respect to airflow when the blades are closed (see FIG. 7). In particular, when the damper assembly 20 is closed, leading edge 60 of upper damper blade 56 is biased downwardly and trailing edge 62 of lower damper blade 58 is biased upwardly such that edges 60 and 62 abut each other to form a seal with respect to each other.
[0028] Referring also to FIG. 3, damper blades 56 and 58 present downwardly facing triangular grooves 67 that extend centrally along the transverse length of the blades. Grooves 67 define the axes of rotation for blades 56 and 58 . A brackets 64 is mounted, preferably via rivets 65 , onto the lower surface of each damper blade 56 and 58 at their corresponding transverse outer ends. Brackets 64 also define triangular grooves 66 that are upwardly facing and aligned with grooves 67 of blades 56 and 58 to define corresponding noncircular, and preferably rectangular, and more preferably square, bores 68 . Bores 68 receive upper and lower noncircular shafts 70 and 70 ′ which, in turn, are rotatably supported by side walls 23 and 24 (via a bearing or the like). Accordingly, both transverse ends of blades 56 and 58 are rotatably mounted to housing 22 to open and close the damper assembly 20 .
[0029] Blades 56 and 58 are connected to a fusible link assembly 72 that includes a first housing 74 mounted onto the upper surface 59 of lower blade 58 , and a second housing 76 mounted onto the lower surface 61 of upper blade 56 . Housings 74 and 76 are mounted onto blades 56 and 58 on both longitudinal sides of grooves 67 via bolts 78 . Housings 74 and 76 include hooks 80 and 82 , respectively, that are, in turn connected to the outer ends 88 of a fusible link 86 . In particular, hook 80 extends upwardly from one outer end 75 of housing 74 , and in particular extends towards the opposite outer end 77 of housing 76 . Hook 82 extends downwardly from outer end 77 of housing 76 towards outer end 75 of housing 74 . Fusible link 86 defines apertures 84 extending through its outer ends 88 that are engaged by hooks 80 and 82 . Fusible link 86 thus extends diagonally with respect to housings 74 and 76 , and prevents blades 56 and 58 from rotating in response to a torsional force F (clockwise as illustrated in FIG. 2 and counterclockwise as illustrated in FIG. 1). It should be appreciated that the orientation of fusible link 86 could be reversed depending on the direction of force F.
[0030] Fusible link assembly 72 thus supports damper blades 56 and 58 , and maintains damper assembly 20 in its open position to permit fluid to pass unobstructed through opening 50 . However, when the fusible link 86 fails in a predetermined manner in response to a predetermined stimulus, damper blades 56 and 58 rotate to the closed position as illustrated in FIG. 7 to prevent fluid from traveling through damper assembly. Fusible link assembly 72 thus provides a removable mechanical connection between damper blades 56 and 58 that interferes with the blades' ability to close during normal operation. The present invention contemplates that fusible link assembly 72 can be heat responsive, or responsive to any other stimulus to fail in a predetermined manner.
[0031] Referring now to FIGS. 1 and 4 in particular, damper assembly 20 further includes a damper latch mechanism 21 that is mounted onto side wall 23 , though it should be easily appreciated that mechanism 21 could be mounted at any suitable location. Latch mechanism 21 supports rotation of damper blades 56 and 58 and locks the damper blades 56 and 58 in position once the blades have been closed, thereby increasing the damper assembly 20 strength, as will now be described.
[0032] Latch mechanism 21 includes an upper rectangular pivot arm 90 that is pivotally mounted at a first outer end 92 to side wall 23 . In particular, outer end 92 receives shaft 70 , and is swaged or otherwise mechanically coupled to shaft 70 , such that upper damper blade 56 , shaft 70 , and arm 90 rotate together. Upper pivot arm 90 extends upwardly and longitudinally forward from outer end 92 when damper blades 56 and 58 are open. Arm 90 is connected at a second outer end 96 to a linking member 98 , which joins upper pivot arm 90 to a lower pivot plate 100 . Linking member 98 extends vertically between arm 90 and pivot plate 100 , and is disposed adjacent flange 42 . Member 98 defines an upper end 97 that is pivotally connected to outer end 96 of upper pivot arm 90 , and a lower end 99 that is pivotally connected to lower pivot plate 100 . Plate 100 is pivotally mounted at its upper, longitudinally rearward, end through side wall 23 via shaft 70 ′. In particular, plate 100 receives shaft 70 ′ in the manner described above with reference to pivot arm 90 .
[0033] Lower pivot plate 100 includes a lip 108 that extends rearwardly from the longitudinally rear edge of pivot plate 100 at a location below shaft 70 ′. Lip 108 is connected to a first lower end 110 of a spring member 112 that extends upwardly and longitudinally rearward, and has an upper end 114 that is connected to flange 44 at a location above shaft 70 ′. It should be appreciated, however, that upper end 114 of spring can be positioned anywhere such that it biases the dampers towards their closed position. In this regard, the upper end 114 of the spring is said to be supported by (or in mechanical communication with) the housing 22 , and the lower end 110 of spring is in mechanical communication with blades 56 and 58 , and further in mechanical communication with plate 100 . Accordingly, spring 112 imparts a torsional force F to lower pivot arm in the counterclockwise direction (with respect to the view taken in FIG. 4). The fusible link assembly 72 resists force F to prevent damper blades 56 and 58 from rotating, as described above.
[0034] Lower pivot plate 100 is connected to a locking member 116 interposed between side wall 23 and plate 100 . In particular, locking member 116 is pivotally connected to the inner surface of the lower end of pivot plate 100 via a pin 118 . Pin 118 is disposed below and upstream of shaft 70 ′. Locking member 116 includes a central body portion 120 and first and second arms 122 and 124 , respectively. When locking member is in its neutral position (i.e., when damper blades 56 and 58 are open), first arm 122 extends upwardly and downstream from body portion 120 and second arm 124 extends downwardly and downstream from body portion 120 . A hook 126 extends downwardly from the distal end of second arm 124 . A vertically elongated groove 127 extends through flange 44 and defines a lower lip 129 that is substantially horizontally disposed with respect to shaft 70 ′. Hook 126 is configured to engage lip 129 when the damper blades 56 and 58 are closed.
[0035] A spring member 128 is connected at one end to the central body portion 120 . The other end of spring 128 is connected to the longitudinal rearward end of lower pivot plate 100 at a location below shaft 70 ′ and above pin 118 . Spring member 128 is compressed, and extends primarily horizontally, and slightly vertically, when blades 56 and 58 are open.
[0036] The operation of damper assembly 20 will now be described with particular reference to FIGS. 4 - 7 . During normal operating conditions illustrated in FIG. 4, fusible link assembly 72 prevents force F from rotating pivot arm 90 and plate 100 and corresponding damper blades 56 and 58 to their closed positions. Accordingly, blades 56 and 58 extend horizontally, thereby allowing the passage of air through opening 50 . However, if the temperature of fusible link 86 becomes elevated beyond a maximum permissible threshold (well known in the art), the fusible link fails, thus removing the impediment to counterclockwise rotation under spring force F.
[0037] Because linking member 98 is pivotally mounted to the transverse outer surfaces of pivot arm 90 and pivot plate 100 at joints 104 and 106 , respectively, rotation of lower pivot plate 100 in the direction of force F translates linking member 98 to correspondingly rotate upper pivot arm 90 which, in turn, rotates damper blades 56 and 58 . Accordingly, referring now to FIG. 5, when fusible link 86 fails, spring force F biases lower pivot plate 100 in the counterclockwise direction, which translates linkage member 98 downwardly, thereby causing upper pivot arm 90 to rotate in the counterclockwise direction along with lower pivot plate 100 . The rotation of pivot arm 90 and plate 100 causes shafts 70 and 70 ′ along with corresponding damper blades 56 and 58 to rotate counterclockwise along the direction of Arrow A towards their closed position. As blades 56 and 58 rotate to their closed positions, pin 118 is translated primarily longitudinally downstream towards flange 44 and slightly downwardly while spring 128 remains compressed.
[0038] Referring to FIG. 6, as pivot plate 100 rotates counterclockwise, the outer edge of hook 126 contacts the transverse inner surface of flange 44 . As pivot arm 100 continues to rotate counterclockwise, spring 128 is extended, and imparts a compressive spring force F 2 that biases locking member 116 clockwise about pin 118 . The interference between hook 126 and flange 44 , however, prevents further clockwise rotation of locking member 116 . However, as lower pivot plate 100 continues to rotate counterclockwise, pin 118 is translated downstream and upwardly, thereby causing arm 118 and hook 126 to correspondingly translate upwardly towards lower lip 129 of groove 127 . It should be appreciated that spring force F 2 continues to increase as lower pivot arm 100 continues to rotate counterclockwise with respect to locking member 116 .
[0039] Referring now to FIG. 7, spring force F continues to rotate arms 100 and 90 along with damper blades 56 and 58 until the leading edge 60 of upper damper blade 56 engages the trailing edge 62 of lower damper blade 58 , thereby closing the damper assembly 20 and preventing fluid from flowing through ductwork. The components of latch mechanism 21 are configured to enable hook 126 to engage groove 127 as blades 54 and 56 close. In particular, hook 126 slips over and catches lower lip 129 under clockwise spring force F 2 which prevents hook 126 from becoming disengaged from the lower lip 129 . If it becomes desirable to disengage hook 126 from lip 129 in order to reset the damper blades 56 and 58 in their open position, a user can manually rotate hook 126 counterclockwise away from lip 129 .
[0040] The components of latch mechanism 21 are sized and configured such that hook 126 and lip 129 become engaged once blades 54 and 56 rotate to their fully closed position under spring force F. The interlock between hook 126 and lip 129 further maintains the closed position of blades 54 and 56 and strengthens the resulting seal. Additionally, spring force F 2 biases locking member 116 clockwise which, in turn, maintains the interlock between hook 126 and lip 129 . Damper assembly 20 thus provides enhanced strengthening features to prevent damper blades 54 and 56 from opening after fusible link 86 fails. The overall reliability of the damper assembly 20 is thus increased over conventional damper assemblies.
[0041] Advantageously, damper latch mechanism 21 is constructed to be installed integrally with damper assembly 20 . In particular, referring to FIGS. 1 and 4, locking member 116 is attached to the lower pivot plate which is conventionally used during normal operation of a damper assembly. Spring 128 may then be connected from lower pivot arm 100 to locking member, and notch 127 may be formed in flange 44 . Accordingly, the present invention includes the construction of damper assembly 20 along with the modification of a conventional damper assembly by installing damper latch mechanism 21 to maintain the damper blades 56 and 58 in their closed position upon failure of the fusible link. Furthermore, because locking member 116 is installed at a location transversely inwardly of lower pivot plate 100 , damper latch mechanism 21 adds only minimal size to conventional damper assemblies.
[0042] It should be appreciated, however, that latch mechanism 21 as described above is only one possible configuration, and that the present invention is not intended to be limited to the latch mechanism described above. Rather, the present invention is intended to broadly cover any mechanism that prevents the damper blades from inadvertently opening once they have closed. For instance, referring now to FIG. 8, damper assembly 20 is illustrated similar to the assembly described above. However, the latch mechanism 21 is constructed in accordance with an alternate embodiment.
[0043] In particular, lower plate 100 defines a lower edge 113 that extends generally longitudinally when damper blades 56 and 58 are in the open position. A flange 115 extends outwardly from edge 113 that provides a catch for plate 100 . Flange 115 connects to an outer edge 117 that provides the outer edge of lip 108 . A plate 119 , formed from steel or any other suitable material, includes a base 121 and a bent section 123 extending upwardly and upstream from the base. Base 121 is connected to flange 44 via rivets 125 , or the like. A handle 131 extends generally downstream, and slightly upwardly, from bent section 123 . Handle 131 extends through an opening (not shown) in flange 44 , and thus extends outside the housing so as to be accessible to a user. Bent section 123 defines an outer edge 133 that provides a follower over outer edge 117 , which provides a cam surface as will now be described.
[0044] During operation, when blades 56 and 58 are biased closed in the manner described above, plate 100 rotates counterclockwise under force F. As plate 100 rotates, lip 108 engages plate 119 , thereby causing edge 133 to follow over cam surface 117 . Lip 108 and plate 119 are sized and shaped such that, as blades 56 and 58 become fully closed, edge 133 snaps over flange 115 . The interference between edge 133 and flange 115 locks plate 100 and blades 56 and 58 with respect to clockwise rotation. If it becomes desirable to reset damper blades 56 and 58 to their open position, a user can apply a downwards force to the exposed end of handle 131 , thereby rotating edge 133 clockwise and removing edge 133 from engagement with flange 115 .
[0045] The latch mechanisms 21 described above are only examples of a number of designs that are intended to fall within the scope of the present invention. For example, the present invention contemplates that a damper blade itself could provide a latch that catches on a member protruding from within the housing when the blade closes to prevent the blade from opening. Accordingly, unless otherwise noted, the present invention is intended to include any latch mechanism that engages to resist counter-movement of the damper blade towards the open position once the damper blade has closed. More specifically, the latch mechanism can include a latching member that is in mechanical communication with the housing or the damper blade, and a corresponding catch that is in mechanical communication with the damper blade or the housing, respectively, that creates a mechanical interference to resist counter-movement of the damper blade(s) towards the open position once the damper blade has closed.
[0046] One skilled in the art will appreciate that damper assemblies are available having a pair of damper blades, as described above, or alternatively with one damper blade that opens and closes to block the ductwork, or alternatively still with more than two damper blades that rotate in concert. The present invention recognizes that all such damper assemblies would benefit by the strengthening features of the present invention. The present invention is thus intended to encompass any damper assembly that can benefit by a locking member that becomes engaged when the damper blade(s) are closed to support the closed position of the damper assembly and resist the blades from opening.
[0047] The invention has been described in connection with what are presently considered to be the most practical and preferred embodiments. However, the present invention has been presented by way of illustration and is not intended to be limited to the disclosed embodiments. Accordingly, those skilled in the art will realize that the invention is intended to encompass all modifications and alternative arrangements included within the spirit and scope of the invention, as set forth by the appended claims.
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A damper assembly is provided having at least one damper blade that operates in a normally open position. A fusible link is connected to the damper blade to maintain the damper blade in the open position against a biasing force tending to close the damper blade. The fusible link fails upon an occurrence of a predetermined condition. A damper mechanism is provided including a locking mechanism linked to the damper blade that resists opening of the damper blade when the blade has closed due to failure of the fusible link.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a contact material for a vacuum valve and a method of manufacturing the same.
2. Description of the Related Art
The most important properties which contact material for vacuum valves is required to have are the three basic requirements of anti-welding property, voltage withstanding capability and current interrupting property. Further important requirements are to show low and stable rise in temperature and low and stable contact resistance. However, it is not possible to satisfy all these requirements by a single metal, as some of them are contradictory. Consequently, many of the contact materials that have been developed for practical use consist of combinations of two or more elements so as to complement their mutual deficiencies in performance, and to match specific applications such as large-current use or high voltage-withstanding ability. However, performance requirements have become increasingly severe and the present situation is such that these materials are unsatisfactory in some respects. A marked recent tendency is towards expansion of the use of these materials to capacitor circuits. Corresponding development and improvement of contact materials is an urgent task.
In order to cope with this, contact materials have previously been employed consisting of copper, as conductive constituent, combined with tungsten, molybdenum, tantalum or niobium, which are high melting point materials and in general provide excellent withstand-voltage capability.
Such Cu-W or the like contact materials can be applied in fields where a certain degree of withstand-voltage performance is required. However, they are subject to the problem of restriking in more severe high withstand-voltage regions and circuits in which inrush currents occur. The reason for this is insufficient adhesive strength between the grains of the arc-proof material and the conductive constituent, owing to insufficient wetting of the arc-proof material by the conductive constituent.
Specifically, restriking occurs, even though the electrodes are in open condition, because particles of arc-proof material get electrically charged and are discharged from the surface of the contacts, and because gas is emitted from pores produced in the interior of the contacts by insufficient wetting. Furthermore, when local welding takes place due to radio frequency currents etc. generated when the circuit is closed, since the interface between the aforementioned arc-proof material and conductive constituent is weak and local pores are present, transfer to the contact surface occurs when the electrodes are separated. This causes electric field concentrations etc., which may result in restriking. Such restriking may cause malfunctioning of the circuit system, resulting for example in cut-off of power. In particular, in capacitor circuits, a voltage of twice the ordinary circuit voltage is applied, so the problem of the withstand-voltage characteristic of the contacts, in particular, suppression of restriking has become prominent.
As described above, the reason for occurrence of restriking is insufficient strength of adhesion between the grains of arc-proof material and the conductive constituent, due to insufficient wetting of the arc-proof material with the conductive constituent. It is therefore vital to reduce the frequency of occurrence of restriking by increasing the interface strength and reducing internal pores.
SUMMARY OF THE INVENTION
Accordingly, one object of this invention is to provide a contact material for a vacuum valve, whereby the frequency of occurrence of restriking is reduced.
Another object of this invention is to provide a method of manufacturing a contact material for a vacuum valve, whereby the frequency of occurrence of restriking is reduced.
In order to achieve the aforementioned object, the essence of this invention consists in the addition to the arc-proof constituent and conductive constituent of the auxiliary constituent consisting of at least one of chromium, titanium, yttrium, zirconium, cobalt, and vanadium, in order to strengthen adhesion of the arc-proof constituent and conductive constituent.
These and other objects of this invention can be achieved by providing a contacts material for vacuum valve including an arc-proof constituent having at least one component selected from the group consisting of tantalum, niobium, tungusten and molybdenum and an auxiliary constituent having at least one component selected from the group consisting of chromium, titanium, yttrium, zirconium, cobalt and vanadium. The contact material further includes a conductive constituent having at least one component selected from the group consisting of copper and silver. An amount of the arc-proof constituent is from 25% to 75% by volume. A total amount of the arc-proof constituent together with the auxiliary constituent is no more than 75% by volume. In addition, an amount of the conductive constituent comprises the balance.
These and other objects of this invention can further be achieved by providing a method of manufacturing the contacts material as described above including the step of manufacturing a skeleton with the arc-proof constituent and the auxiliary constituent. The method further includes the step of infiltrating the skeleton with an infiltration material to obtain the contact material.
These and other objects of this invention can further be achieved by providing a method of manufacturing the contacts material as described above including the step of manufacturing a skeleton with the arc-proof constituent, the auxiliary constituent and the conductive constituent. The method further includes the step of infiltrating the skeleton with an infiltration material to obtain the contacts material.
These and other objects of this invention can also be achieved by providing a method of manufacturing the contact material as described above including the steps of manufacturing a skeleton with the arc-proof constituent and infiltrating the skeleton with an infiltration material to obtain the contact material. The infiltration material includes the conductive constituent added with the auxiliary constituent.
These and other objects of this invention can further be achieved by providing a method of manufacturing the contact material as described above including the step of mixing powders of the arc-proof constituent, the auxiliary constituent and the conductive constituent to form a mixed contacts material powder. The method further includes the steps of forming the mixed contacts material powder to form a molded body and sintering the molded body to obtain the contacts material.
Specifically, the reason why the adhesion between the arc-proof constituent and the conductive constituent in the contact material is increased by the addition of the auxiliary constituent to the arc-proof constituent and conductive constituent is described below. In the case of the conventional contact material, in which the arc-proof material such as tungsten is employed, insufficient interface strength was obtained owing to its complete failure to form a solid solution with or to react with a conductive constituent such as copper. In the case of the contact material of this invention there is added the auxiliary constituent that reacts with the arc-proof material and also reacts with the conductive constituent. As a result, the arc-proof constituent and conductive constituent are more tightly adhered, so that restriking can be prevented, because a reduction is achieved in discharge from the surface of the arc-proof grains, generation of marked unevenness on occurrence of welding, and pores in the interior of the contacts.
BRIEF DESCRIPTION OF THE DRAWINGS
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:
FIG. 1 is a cross-sectional view of a vacuum valve to which a contacts material for the vacuum valve according to this invention is applied; and
FIG. 2 is an enlarged cross-sectional view of the electrode portion of the electrode portion of the vacuum value shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of this invention are described below with reference to the drawings. FIG. 1 is cross-sectional view of a vacuum valve. FIG. 2 is a view to a larger scale of the electrode portion of the vacuum valve shown in FIG. 1.
In FIG. 1, a circuit breaking chamber 1 is constituted by an insulating vessel 2 formed practically on a cylinder by insulating material and metal covers 4a, 4b provided at both ends thereof, with interposition of sealing fitments 3a and 3b, the chamber being maintained under vacuum.
The circuit breaking chamber 1 has arranged within it a pair of electrodes 7 and 8 mounted at facing ends of conductive rods 5 and 6. For example upper electrode 7 is the fixed electrode, while lower electrode 8 is the movable electrode. A bellows 9 is fitted to conductive rod 6 of this electrode 8, so that movement in the axial direction of electrode 8 can be performed while maintaining a vacuum-tight environment within circuit breaking chamber 1. A metal arc shield 10 is provided at the top of the bellows 9 to prevent bellows 9 being covered by arc vapour. A metal arc shield 11 is provided in circuit breaking chamber 1 so as to cover electrodes 7 and 8, to prevent insulating vessel 2 being covered by arc vapor.
As shown in FIG. 2, electrode 8 is fixed to conductive rod 6 by a brazing portion 12, or is press-fitted by caulking. A contact 13a is mounted on electrode 8 by brazing a portion 14. Essentially the same construction is adopted for electrode 7.
Next, examples of a method of manufacturing contact material according to this invention will be described. Methods of manufacturing contact material can be broadly classified into the infiltration method, wherein the conductive constituent is melted and allowed to flow into a skeleton formed of the arc-proof powder etc., and the sintering method, in which the powders are mixed in prescribed proportions and molded and sintered.
Compared with the prior art methods, the method of manufacture according to this invention has the following characteristics. Specifically, in the case of the infiltration method, the characteristic feature is that a skeleton is manufactured by sintering in for example vacuum atmosphere a mixed powder consisting of the arc-proof powder and the third element powder (auxiliary constituent powder), and the conductive constituent is infiltrated into this skeleton in for example a vacuum atmosphere to manufacture contact material. It is also possible to manufacture the contacts material by infiltrating a conductive constituent, to which the third element has been added, into a skeleton manufactured of arc-proof powder only. In the case of the sintering method, the characteristic feature is that the contact material is manufactured by sintering for example in a vacuum atmosphere a mixed powder consisting of arc-proof powder, conductive powder and a third element powder blended in prescribed amounts. In both the infiltration and sintering methods, the contacts can be manufactured using a composite powder obtained by coating the surface of the arc-proof constituent powder with the third element, or an alloy powder of the arc-proof element and the third element.
Next, a method of evaluation and the conditions for the evaluation will be explained, whereby concrete examples, to be described, are obtained. With the above described matters in view, a comparison was made between contact material according to this invention and conventionally manufactured contact material, in terms of frequency of occurrence of restriking. The disc-shaped sample of contact material of diameter a diameter of 30 mm, and a thickness of 5 mm is fitted in a demountable-type vacuum valve. Then, measurements were carried out by measuring the frequency of occurrence of restriking on breaking a 60 kV×500A circuit 2000 times by the demountable-type vacuum valve. The results were expressed as a percentage occurrence of restriking. For fitting the contact, only baking heating (450° C.×30 minutes) was performed. Brazing material was not used, and the heating which would accompany this was not performed.
[TABLE 1]______________________________________ Chemical Percentage constituents occur- Method (vol %) rence of of manu- Nb Cr Cu restriking facture Notes______________________________________Comparative 25 0 Bal 1-2% sinteringexample 1Example 1 25 1 Bal 0.8% sinteringExample 2 25 25 Bal 0.5% infiltrationExample 3 25 50 Bal 0.5% infiltrationComparative 25 65 Bal 0.8% infiltration Largeexample 2 contact resistance______________________________________
[TABLE 2]______________________________________Chemical Percentageconstituents occur- Method(vol %) rence of of manu-Ta Ti Cu restriking facture Notes______________________________________Compar- 15 1 Bal 0.8% sintering insufficientative breakingexample 3 abilityExample 4 25 1 Bal 0.8% sinteringExample 5 50 1 Bal 0.5% infiltrationExample 6 70 1 Bal 0.5% infiltrationCompar- 90 1 Bal 0.8% infiltration Largeative contactexample 4 resistance______________________________________
[TABLE 3]______________________________________ PercentageChemical constituents occur- Method(vol %) rence of of manu-W Mo Y Zr Co Cu Ag restriking facture______________________________________Exam- 50 0 0 0 5 30 15 0.8% infil-ple 7 trationExam- 25 25 1 1 0 Bal 0 0.5% infil-ple 8 tration______________________________________
[TABLE 4]______________________________________ Chemical constituents Method of Percentage of (vol %) manufacture restriking______________________________________Example 9 45Nb--5Cr--Cu sintering 0.5%Example 10 45Nb--1Cr--Cu sintering 0.5%Example 11 20Nb--20Cr--Cu sintering 0.5%Example 12 25Nb--3Cr--Cu sintering 0.8%______________________________________
In the manufacture of Table 1 through Table 3, a single metal powder was employed. The skeleton for the infiltration method was manufactured only of arc-proof powder and auxiliary constituent powder. Oxygen-free copper and vacuum-melted Ag/Cu alloy were employed as infiltration material.
Examples 1-3, Comparative Examples 1-2 (refer to Table 1)
Contacts were manufactured with the niobium content of the arc-proof material fixed at 25 volume % but with added amounts of the chromium auxiliary constituent of 0, 1, 25, 50 and 65 volume % (comparative example 1, examples 1, 2 and 3 and comparative example 2, respectively). The raw material powder used consisted of a mixture of niobium powder and chromium powder. Comparative example 1 and example 1 were manufactured by the sintering method. In more detail, manufacture was carried out by sintering at prescribed temperature after mixing and molding niobium powder, chromium powder and copper powder to prepare samples to be tested. The detailed conditions for manufucturing these samples are described as CONDITION 1.
CONDITION 1 for Example 1 and Comparative Example 1
A Nb powder, a Cr powder and a Cu powder having an average grain size of 100, 50 and 30 micrometers, respectively, are provided. These are mixed for 12 hours in a ball mill. The resulting mixture is molded with a molding pressure of 8 metric tons per square centrimeter. The resulting molded body is sintered at a temperature of 1050° C. for 3 hours under a vacuum of 1.0×10 -2 Pa to obtain the sample of the contact material.
Examples 2 and 3 and comparative example 2 were manufactured by the infiltration method. In more detail, a skeleton was manufactured by mixing, forming and sintering niobium powder and chromium powder. Next, samples were prepared by infiltration of oxygen-free copper into the skeleton. The detailed conditions for manufacturing these samples are described in CONDITION 2.
CONDITION 2 for Examples 2 and 3 and Comparative Example 2
A Nb powder and a Cr powder having an average grain size of 100 and 50 micrometers, respectively, are provided. These are mixed for 12 hours in a ball mill. The resulting mixture is molded with a molding pressure of 0.5, 2 and 5 metric tons per square centimeter, for example 2, example 3 and comparative example 2, respectively. The resulting molded body is sintered at a temperature of 1200° C. for 1 hours under a vacuum of 1.0×10 -2 Pa to obtain a skeleton. The skeleton is infiltrated by oxygen-free copper at a temperature of 1130° C. for 0.5 hour under a vacuum of 1.0×10 -2 Pa to obtain the sample of the contact material.
The probability of occurrence of restriking was measured after processing these samples and mounting them in a demountable-type vacuum valve. As shown in Table 1, the result was that, whereas in comparative example 1, in which no chromium was added, the probability of occurrence of restriking was 1-2%, in examples 1, 2, and 3, in which 1, 25 and 50% chromium was added, it was 0.5-0.8%, representing an improvenent. The probability of occurrence of restriking, at 0.8%, was also improved in the case of comparative example 2, in which 65% chromium was added. But this comparative example 2 is problematic in practical use because it has a large contact resistance owing to the dearth of conductive constituent. For purposes of comparison, an attempt was also made to manufacture Nb-Cu contact material by the infiltration method with no chromium addition. However, perhaps infiltration could not be achieved due to the effect of surface oxide.
Examples 4-6, Comparative Examples 3-4 (see Table 2)
Contact materials were manufactured with the addition of the auxiliary constituent titanium fixed at 1 volume % but with contents of the arc-proof constituent tantalum of 15, 25, 50, 70 and 90 volume % (comparative example 3, examples 4, 5 and 6 and comparative example 4, respectively). In the case of comparative example 3 and example 4, the method of manufacturing the contact material was the sintering method. The detailed conditions for manufacturing these samples are described in CONDITION 3.
CONDITION 3 for Example 4 and Comparative Example 3
A Ta powder, a Ti powder and a Cu powder having an average grain size of 100, 50 and 30 micrometers, respectively, are provided. The following process is the same as that of the CONDITION 1.
In the case of examples 5 and 6 and comparative example 4, the infiltration method was employed. The detailed conditions for manufacturing these samples are described in CONDITION 4.
CONDITION 4 for Examples 5 and 6 and Comparative Example 4
A Ta powder and a Ti powder having an average grain size of 100 and 50 micrometers, respectively, are provided. These are mixed for 12 hours in a ball mill. The resulting mixture is molded with a molding pressure of 0.5, 2 and 5 metric tons per square centimeter, for example 5, example 6 and comparative example 4, respectively. The following process is the same as that of CONDITION 2.
In the case of all the samples, an improvement with respect to the restriking probability was seen, this being 0.5-0.8%. However, in the case of comparative example 3, in which the tantalum content was 15%, the circuit-breaking capability was much decreased, and in the case of comparative example 4 in which the tantalum content was 90%, the contact resistance became large as in comparative example 2 referred to above, to the extent that this sample could not be incorporated in a practical vacuum valve.
Examples 7-8 (see Table 3)
In Table 1 examples using Nb - Cr - Cu systems and in Table 2 examples using Ta - Ti - Cu system were described. However, reduction in the restriking probability can likewise be obtained by the use of tungsten and molybdenum as arc-proof material instead of niobium and tantalum, and by the use of yttrium, zirconium, cobalt or vanadium as an auxiliary constituent instead of chromium or titanium. Also silver could be used as conductive constituent instead of copper. Example 7 is an example in which contact consisting of 50 volume % W - 5% Co - 30% Cu - 15% Ag were manufactured by the infiltration method. Example 8 is an example in which contact consisting of 25% W - 25% Mo 1% Y - 1% Zr-Cu (Balance) were manufactured by the infiltration method. The detailed conditions for manufacturing these samples are described in CONDITION 5.
CONDITION 5 for Examples 7 and 8
A W powder, a Co powder, a Cu powder and an Ag powder having an average grain size of 3, 5, 30 and 30 micrometers, respectively, are provided for example 7. A W powder, a Mo powder, a Y powder, a Zr powder and a Cu powder having an average grain size of 3, 3, 30, 30 and 30 micrometers, respectively, are provided for example 8. The following process is the same as that of the example 2 in the CONDITION 2. Both of these contact were useful as they offered low restriking probabilities of 0.8% and 0.5%.
From the results of examination of the above examples it can be seen that the frequency of restriking can be reduced not merely by the compositions of the example but by employing tantalium, niobium, molybdenum or tungsten as arc-proof material, chromium, titanium, yttrium, zirconium, cobalt or vanadium as auxiliary constituent, and copper or silver as conductive constituent.
Examples 9-12 (see Table 4)
Next, the method of manufacture will be examined. Example 9 is an example in which a skeleton was manufactured by blending and mixing niobium powder and chronium poweder in the ratio 9:1 and this was then infiltrated with oxygen-free copper. Example 10 is an example in which a skeleton was manufactured consisting of niobium powder only, and this was then infiltrated with a previously prepared 2% Cr - Cu alloy. Example 11 is an example in which a skeleton was prepared by mixing and sintering Nb/Cr alloy powder with Cu powder and this was then infiltrated with further oxygen-free copper. In example 12, contact were manufactured by coating the surface of niobium powder with chromium and then mixing this with copper powder and molding, followed by sintering.
The detailed conditions for manufacturing these samples are described in CONDITIONs 6, 7, 8 and 9.
CONDITION 6 for Example 9
A Nb powder and Cr powder having an average grain size of 100 and 50 micrometers, respectively, are provided. The Nb powder and the Cr powder are blended in the ratio of 9:1 by volume and then mixed for 12 hours in a ball mill. The resulting mixture is molded with a molding pressure of 0.5 metric tons per square centimeter. The resulting molded body is sintered at a temperature of 1200° C. for 3 hours under a vacuum of 1.0×10 -2 Pa to obtain a skeleton. The skeleton is infiltrated by oxygen-free copper at a temperature of 1130° C. for 0.5 hour under a vacuum of 1.0×10 -2 Pa to obtain the sample of the contact material.
CONDITION 7 for Example 10
A Nb powder having an average grain size of 100 micrometers is molded with a molding pressure of 0.5 metric tons per square centimeter. The resulting molded body is sintered at a temperature of 1200° C. for 3 hours under a vacuum of 1.0×10 -2 Pa to obtain a skeleton. 2% Cr - Cu alloy is prepared by melting Cr and Cu under a vacuum of 1.0×10 -2 Pa, in advance. The skeleton is infiltrated by 2% Cr - Cu alloy at a temperature of 1130° C. for 0.5 hour under a vacuum of 1.0×10 -2 Pa to obtain the sample of the contact material.
CONDITION 8 for Example 11
50 wt% Nb - Cr alloy is crushed into an alloyed powder having an average grain size of 100 micrometers. The alloyed powder and a Cu powder having an average grain size of 30 micrometers are mixed for 12 hours in a ball mill. The resulting mixture is molded with a molding pressure of 3 metric tons per square centimeter. The resulting molded body is sintered at a temperature of 1200° C. for 1 hour under a vacuum of 1.0×1.0 -2 Pa to obtain a skeleton. The skeleton is infiltrated by oxygen-copper at a temperature of 1130° C. for 0.5 hour under a vacuum of 1.0×10 -2 Pa to obtain the sample of the contact material.
CONDITION 9 for Example 12
A Nb powder having an average grain size of 100 micrometers is coated with Cr to form a composite powder, in which Nb and Cr are in the ratio of 9:1 by volume. The composite powder and a Cu powder having an average grain size of 30 micrometers are mixed for 12 hours in a ball mill. The resulting mixture is molded with a molding pressure of 8 metric tons per square centimeter. The resulting molded body is sintered at a temperature of 1050° C. for 3 hours under a vacuum of 1.0×10 -2 Pa to obtain the sample of the contact material.
The restriking probabilities of these contact were in each case 0.5-0.8% i.e. good results were obtained.
When the cross-sectional structure of the contact materials manufactured by these various methods was observed using an optical microscope and an electron microscope, it was found that in all cases the periphery of the arc-proof material tended to be surrounded by the auxiliary constituent, confirming that the auxiliary constituent plays the role of bonding the arc-proof material and the conductive constituent. In particular, this trend was very noticeable in contact material manufactured by the infiltration method. It can be inferred that this result is reflected in the fact that, whereas the probability of occurrence of restriking is about 0.8% in the case of contact material manufactured by sintering, that of contact material manufactured by infiltration is 0.5%. When manufacturing contact material by the sintering method, to suppress occurrence of restriking, it is therefore desirable to have the sintering temperature to be as close to the melting point as possible. But contact material even manufactured by the sintering method can also lower the probability of restriking sufficiently.
Also, on subjecting the conductive constituent matrix constructed with conductive constituent to examination of the cross-sectional structure, it was found that in many places the auxiliary constituent had melted or precipitated within the conductive constituent matrix, resulting in firm adhesion between the auxiliary constituent and the conductive constituent. This phenomenon too was found to be particularly noticeable in contact material produced by the infiltration method.
From the results of examination of the above examples, it is clear that, in the method of manufacture according to this invention, similar results can be obtained not just in the present examples but also by partial combinations of these examples.
As described above, with this invention, contact material for a vacuum valve, and a method of manufacturing it, can be obtained which is of high reliability and whereby the probability of restriking is reduced, owing to the increased strength of adhesion between arc-proof constituent and conductive constituent which is obtained thanks to the auxiliary constituent.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.
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A contacts material for a vacuum valve including an arc-proof constituent having at least one component selected from the group consisting of tantalum, niobium, tungsten and molybdenum and an auxiliary constituent having at least one component selected from the group consisting of chromium, titanium, yttrium, zirconium, cobalt and vanadium. The contact material further includes a conductive constituent having at least one component selected from the group consisting of copper and silver. The amount of the arc-proof constituent is from 25% to 75% by volume. The total amount of the arc-proof constituent together with the auxiliary constituent is no more than 75% by volume. The amount of the conductive constituent is the balance.
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CROSS REFERENCE TO OTHER APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 11/809,364, entitled INTENSITY CHANGING WITH REDUCED FLICKER FOR DIGITALLY-CONTROLLED LIGHTING filed May 31, 2007 which is incorporated herein by reference for all purposes, which claims priority to U.S. Provisional Application No. 60/856,560, entitled SMOOTH DIMMING OF LEDS filed Nov. 3, 2006 which is incorporated herein by reference for all purposes.
BACKGROUND OF THE INVENTION
[0002] Modern lighting control systems use digital commands to set light source intensity, where the numeric value of each command is an integer ranging from zero through a certain maximum and corresponds to 0 to 100% of the maximum intensity of the light source being controlled. It is often desirable to change the intensity at a metered rate to avoid abrupt transitions. This is accomplished by issuing a series of intensity commands at intervals to approximate the desired ramp. However under certain conditions the individual intensity step changes making up the ramp are visible, which is perceived by the human eye as an irritating flicker. When the light source responds quickly to commands, such as with LEDs (Light-Emitting Diodes), the flicker can be very pronounced. The human eye is relatively insensitive to absolute light levels, but extraordinarily sensitive to abrupt intensity changes. Even the smallest possible change is visible at low intensity levels because the numeric difference between commands is large relative to the value of the commands. For example, the USITT DMX lighting control protocol specifies that each intensity command utilize 8 bits, thus having a range of values from zero to 255. If the current intensity is 1 then changing to a new intensity of 2 represents doubling the brightness and will certainly be visible as an abrupt transition. A typical system today attempts to mitigate this effect by increasing the resolution, using for example 12 or 16 bits per command, but the flicker effect is still visible at lower intensities. Also, higher resolutions have a higher overhead due to the increase in handling the increased number of bits per command. It would be useful to change the intensity of a light source in response to digital commands regardless of intensity and command resolution without an observer being able to notice a flickering of the light source.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] Various embodiments of the invention are disclosed in the following detailed description and the accompanying drawings.
[0004] FIG. 1 is a block diagram illustrating an embodiment of a lighting system capable of a reduced flicker intensity change.
[0005] FIG. 2A is a graph illustrating an embodiment of a low-resolution linear transition ramp as seen in the prior art.
[0006] FIG. 2B is a graph illustrating an embodiment of a high-resolution linear transition ramp as sometimes used in the prior art in an attempt to reduce flicker.
[0007] FIG. 3A is a graph illustrating an embodiment of a non-linear transition ramp between two intensities.
[0008] FIG. 3B is a graph illustrating an embodiment of a non-linear transition ramp between two intensities.
[0009] FIG. 3C is a graph illustrating an embodiment of a non-linear transition ramp between two intensities.
[0010] FIG. 4 is a flow chart illustrating an embodiment of a process for controlling an intensity change.
[0011] FIG. 5 is a block diagram illustrating an embodiment of state data that is maintained by the Controller.
[0012] FIG. 6 is a flow chart illustrating an embodiment of detailed Controller operation.
DETAILED DESCRIPTION
[0013] The invention can be implemented in numerous ways, including as a process, an apparatus, a system, a composition of matter, a computer readable medium such as a computer readable storage medium or a computer network wherein program instructions are sent over optical or communication links. In this specification, these implementations, or any other form that the invention may take, may be referred to as techniques. A component such as a processor or a memory described as being configured to perform a task includes both a general component that is temporarily configured to perform the task at a given time or a specific component that is manufactured to perform the task. In general, the order of the steps of disclosed processes may be altered within the scope of the invention.
[0014] A detailed description of one or more embodiments of the invention is provided below along with accompanying figures that illustrate the principles of the invention. The invention is described in connection with such embodiments, but the invention is not limited to any embodiment. The scope of the invention is limited only by the claims and the invention encompasses numerous alternatives, modifications and equivalents. Numerous specific details are set forth in the following description in order to provide a thorough understanding of the invention. These details are provided for the purpose of example and the invention may be practiced according to the claims without some or all of these specific details. For the purpose of clarity, technical material that is known in the technical fields related to the invention has not been described in detail so that the invention is not unnecessarily obscured.
[0015] Reduced flicker intensity changing for digitally-controlled lighting is disclosed. Digital commands from an external source specify desired light source intensities. Transitions between commanded intensities are performed with reduced flicker by setting the light source intensity to progressive intermediate values over time until the newly commanded value is reached. The intermediate intensity values and the time intervals between them are selected to minimize stepping visibility to the human eye, or flicker, by adjusting the intensity according to a non-linear curve. The non-linear curve includes an average slope of the ramp that is steepest at the beginning of the transition and reduced towards the end of the transition. In some embodiments, the shape of the non-linear curve can be adjusted by a command or a control panel. In some embodiments, the shape of the non-linear curve can be set to approximate the response time of a different light source. If a new command is received before the light source has reached the previously-commanded intensity, the previous command is abandoned and the light source is adjusted from its current intensity to the newly-commanded intensity. In some embodiments, an indication is transmitted back to the external command source when the transition is complete. Reduction of flicker may be disabled for sequential changes to command intensity which are larger than a threshold, allowing the light source to turn on or off quickly when desired. Reduction of flicker can also be enabled or disabled by means of an external command or switch.
[0016] FIG. 1 is a block diagram illustrating an embodiment of a lighting system capable of a reduced flicker intensity change. In the example shown, Command Source 100 issues digital commands for desired intensities to Controller 102 , which is capable of using Electronic Driver 104 to set intensity for Light Source 106 in the range of 0 to 100% of its maximum.
[0017] In some embodiments, command source 100 comprises a lighting control panel that includes one or more controls (e.g., switches, slides, dimmers, value selectors, etc.) for setting the intensities of one or more lights. In some embodiments, command source 100 comprises a computer system including software that creates a virtual lighting control panel that enables one or more virtual controls (e.g., virtual switches, virtual slides, virtual dimmers, virtual value selectors, etc.) for setting the intensities of one or more lights. In some embodiments, command source 100 comprises a computer system with a pre-programmed set of commands that are output to a controller such as controller 102 . In some embodiments, command source 100 comprises a human interface device. In some embodiments, command source 100 provides commands via a data interface.
[0018] In some embodiments, controller 102 is a processor that calculates one or more intensity step values and times corresponding to when the step values are to be taken to achieve a reduced flicker intensity change for light source 106 . In some embodiments, controller 102 uses look up tables to determine intensity step values and times corresponding to when the step values are to be taken. In some embodiments, the look up table entry that is relevant for determining the intensity step value change and the step times depends on the current intensity value and the target intensity value.
[0019] In some embodiments, controller 104 is a pulse width modulated current source that is used to drive light source 106 , where light source 106 is a light emitting diode (LED). In some embodiments, the current source is a constant current source In various embodiments, light source 106 comprises a single LED, multiple LED's, is driven by a single controller unit or multiple controller units, or any other appropriate controller/light source configuration. In various embodiments, light source 106 comprises an incandescent lamp, a florescent lamp, a high intensity discharge lamp, or any other light source technologies in any combination.
[0020] FIG. 2A is a graph illustrating an embodiment of a low-resolution linear transition ramp as seen in the prior art. In the example shown, vertical axis 200 shows light source intensity and horizontal axis 202 corresponds to time. Ramp 204 consists of roughly uniform steps starting at point 206 corresponding to previous intensity I 0 at starting time t 0 , and ending at point 208 corresponding to newly-commanded intensity I 1 at ending time t 1 . These steps include steps in intensity that are visible as flicker, particularly at low intensity levels.
[0021] FIG. 2B is a graph illustrating an embodiment of a high-resolution linear transition ramp as sometimes used in the prior art in an attempt to reduce flicker. In the example shown, vertical axis 220 shows light source intensity and horizontal axis 222 corresponds to time. Ramp 224 consists of roughly uniform steps starting at point 226 corresponding to previous intensity I 0 at starting time t 0 , and ending at point 228 corresponding to newly-commanded intensity I 1 at ending time t 1 . While these the steps are more subtle than those of the low-resolution ramp 204 in FIG. 2A , it can be seen that the ramps have the same shape. Further, the intensity steps include steps in intensity that are visible as flicker, particularly at low intensity levels similar to the situation as depicted in FIG. 2A . Note that many more intensity commands must be issued to generate the high-resolution ramp. One problem that arises is that the maximum rate of intensity commands supported by the physical hardware can constrain the maximum resolution. For example, the ramp may have to skip over some of the intermediate values in order to reach the final intensity within the desired amount of time.
[0022] FIG. 3A is a graph illustrating an embodiment of a non-linear transition ramp between two intensities. In the example shown, the intensity is changed at high resolution using constant time intervals between steps. Vertical axis 300 shows light source intensity and horizontal axis 302 corresponds to time. Ramp 304 consists of steps with decreasing height starting at point 306 corresponding to previous intensity I 0 at starting time t 0 , and ending at point 308 corresponding to newly-commanded intensity I 1 at ending time t 1 . Because the steps get smaller as the transition proceeds the human eye perceives a reduced flicker during the intensity change.
[0023] In some embodiments, the steps with decreasing height are determined using pre-calculated values, where the pre-calculated values depend on the previous intensity I 0 and the newly-commanded intensity I 1 . In some embodiments, a second new intensity is received before the first new intensity, the newly-commanded intensity I 1 , is reached. In this case, the second new intensity becomes the target intensity (e.g., intensity I 1 ) and the current intensity becomes the starting intensity (e.g., intensity I 0 ). In various embodiments, the time interval between the steps is a predetermined value, a number of different values, a set of increasing or decreasing values, or any other appropriate time interval for reducing flicker. In various embodiments, the intensity step values and the time intervals at which the steps occur are selected to follow a predetermined pattern, where the predetermined pattern appears to be visually similar to a type of incandescent lamp, a theater lamp, a strobe lamp, a spot lamp, or any other appropriate lamp type. In various embodiments, the predetermined patterns are selected using a human interface device (e.g., a control panel, a switch, a graphical user interface, etc.), a command via a data interface (e.g., a digital interface, an analog interface, a fiber optic interface, an electrical interface, a wireless interface, a wired interface, an infrared interface, etc.).
[0024] FIG. 3B is a graph illustrating an embodiment of a non-linear transition ramp between two intensities. In the example shown, the intensity is changed by constant increments at low resolution using variable time intervals between steps. Vertical axis 320 shows light source intensity and horizontal axis 322 corresponds to time. Ramp 324 consists of steps with increasing width starting at point 326 corresponding to previous intensity I 0 at starting time t 0 , and ending at point 328 corresponding to newly-commanded intensity I 1 at ending time t 1 . Comparing ramp 324 near point 328 in FIG. 3B to ramp 304 near point 308 in FIG. 3A , it can be seen that the vertical increments are larger and the time intervals grow longer towards the end of the ramp. Both ramps of FIGS. 3A and 3B describe transitions that appear to have reduced flicker as compared to the linear ramps of FIGS. 2A and 2B . Note that ramp 304 of FIG. 3A requires higher resolution intensity control than ramp 324 of FIG. 3B . In some embodiments, because lower resolutions are generally easier to calculate than higher resolutions, a less expensive controller can be used with the lower resolution required by FIG. 3B as compared with the higher resolution required by FIG. 3A .
[0025] FIG. 3C is a graph illustrating an embodiment of a non-linear transition ramp between two intensities. In the example shown, the intensity is changed by variable increments using variable time intervals between steps. Vertical axis 340 shows light source intensity and horizontal axis 342 corresponds to time. Ramp 344 consists of steps with both decreasing height and increasing width starting at point 346 corresponding to previous intensity I 0 at starting time t 0 , and ending at point 348 corresponding to newly-commanded intensity I 1 at ending time t 1 . Comparing ramp 344 in FIG. 3C to ramp 304 in FIG. 3A and ramp 324 in FIG. 3B , it can be seen that the resolution along both intensity and time axis is reduced. All ramps of FIGS. 3A , 3 B, and 3 C describe transitions that appear to have reduced flicker as compared to the linear ramps of FIGS. 2A and 2B . In some embodiments, changing both height and width for each step creates transitions that appear to have further reduced flicker as compared to step changes that occur only on one axis. In some embodiments, changing both height and width for each step permits the use of lower intensity resolutions and lower time resolutions for a given degree of reduced flicker. In some embodiments, because lower resolutions are generally easier to calculate than higher resolutions, a less expensive controller can be used with the lower resolution required by FIG. 3C as compared with the higher intensity resolution required by FIG. 3A or the higher time resolution required by FIG. 3B .
[0026] FIG. 4 is a flow chart illustrating an embodiment of a process for controlling an intensity change. In some embodiments, the process of FIG. 4 is executed by controller showing an overview of Controller operation. In the example shown, in 400 a new intensity command is received. In some embodiments, the command is received from a lighting control panel or computer that includes a control panel in software for lighting. In 402 , a non-linear transition ramp between the current light source intensity and the newly-commanded intensity is created. In various embodiments, the ramp is created using a table, a mathematical formula, a piece-wise linear approximation for a curve, or any other appropriate manner of creating a ramp. In 404 , the ramp is output to the electronics driver. The driver drives the light source (e.g., an LED light source) to change the intensity of the light source. Control passes back to 400 . In some embodiments, the process completes when a command is received to shut down. In some embodiments, the transition ramp will be generated in parallel with outputting it to the driver; for example, one or more of the steps within the ramp will be computed and output to the driver before the steps for the entire ramp is calculated. In some embodiments this output step will be terminated early if a new intensity command is available.
[0027] FIG. 5 is a block diagram illustrating an embodiment of state data that is maintained by the Controller. In some embodiments, the state data of FIG. 5 is used by a controller such as controller 102 of FIG. 1 in conjunction with determining a control signal (e.g., a ramp of steps) for a light source (e.g., a LED). In the example shown, Command_Intensity 500 stores the last received intensity command using an 8 bit value. In some embodiments, a Command_Intensity is stored using a different number of bits as appropriate for the light controlling system. Current_Intensity 502 stores the intensity most recently output to the driver using 12 bits, and represents one of the intermediate values in the non-linear ramp. In some embodiments, the number of bits used to store Current_Intensity is selected to allow the transition ramp to be of a higher resolution than the resolution of the command intensity. Scale_Factor 504 affects the shape of the non-linear ramp. The time required for the ramp to change the intensity from the current intensity to the command intensity will depend on Scale_Factor 504 . In some embodiments, Scale_Factor 504 is a constant. In some embodiments, Scale_Factor 504 can be changed dynamically by a command as indicated using a switch or otherwise on a physical or software control panel or from another command source to change the shape of the non-linear ramp. The shape of the non-linear ramp can range from very slow and smooth, to moderately fast and more abrupt, to an immediate transition to the Command_Intensity.
[0028] In some embodiments, a new command intensity is received that causes an immediate (e.g., strobe is selected) light source intensity change to the new command intensity. In some embodiments, if the magnitude of the difference between the new command intensity and the current intensity exceeds a threshold, then the intensity change is set to take place without a ramp (e.g., strobe is selected).
[0029] FIG. 6 is a flow chart illustrating an embodiment of a process for controlling an intensity change. In the example shown, in 600 data structures are initialized. In some embodiments, the data structures include the state variables of FIG. 5 . In the example shown, in 601 a new intensity command is received. In some embodiments, the command is received from a lighting control panel or computer that includes a control panel in software for lighting. In 602 , the difference (i.e., delta) between the current actual intensity of the light source and the desired value most recently commanded is calculated. In 603 , it is determined if the delta is zero. In some embodiments, delta is determined to be zero when the current intensity is substantially equal to the command intensity. If delta is zero, then control passes to 601 . If delta is not zero, then in 604 it is determined if strobe is selected. If strobe is selected, then in 608 Current_Intensity is set to Command_Intensity. Selecting strobe indicates a sudden change in intensity. If strobe is not selected, in 606 scale delta and set Current_Intensity to Current_Intensity plus scaled delta. In some embodiments, delta is scaled using a scale factor in the data structure (e.g., Scale_Factor 504 of FIG. 5 ). In some embodiments, the scaled value is adjusted to be never less than one. In 610 , Current_Intensity is output to the light source driver and control passes to 601 . Since the first delta of a transition ramp is the largest for that ramp, the first intermediate step calculated by scaling will also be the largest. Subsequent differences will be progressively smaller as will the corresponding intensity steps until the ramp is complete. These decreasing differences result in the desired non-linear ramp.
[0030] In some embodiments, the intensity step remains constant and the time interval between intensity changes is scaled to grow longer with each step.
[0031] In some embodiments, the intensity and time steps are scaled or changed in setting the ramp to a command intensity from a current intensity.
[0032] Although the foregoing embodiments have been described in some detail for purposes of clarity of understanding, the invention is not limited to the details provided. There are many alternative ways of implementing the invention. The disclosed embodiments are illustrative and not restrictive.
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A system for changing a light source intensity comprises a processor and a memory. The processor is configured to receive a command intensity for a light source, wherein the light source has a current intensity, and wherein an intensity of the light source is ramped toward the command intensity from the current intensity automatically. The processor is further configured to determine a non-linear curve for the intensity of the light source, wherein at least a portion of the non-linear curve includes a beginning portion slope that is steeper at a beginning of the portion than an end portion slope at an end of the portion and to cause a change of a light source intensity by ramping over a time interval, wherein the light source intensity targets conforming to the non-linear curve for the intensity of the light source. The memory coupled to the processor and configured to provide instructions to the processor.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Priority of U.S. Provisional Patent Application Ser. No. 61/033,926, filed Mar. 5, 2008, incorporated herein by reference, is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
Not applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the handling of oil and gas well drilling fluids, especially in an offshore or marine environment. More particularly, the present invention relates to an improved oil and gas well fluids transfer apparatus that features a first module carrying multiple supply reservoirs for holding different drilling or production fluids and a second, typically smaller supply module for holding one or more resupply modules and wherein a docking station interfaces the two modules, fluid transfer being effected with specially configured piping so that any one reservoir can be filled with a selected resupply reservoir that is docked on the docking station; and wherein a detachable perimeter frame or frames enables load to be transferred to a larger area when all reservoirs are filled or to be filled.
2. General Background of the Invention
In the drilling of oil and gas wells, a large number of different fluids are typically employed. These fluids can include various chemical formula that assist the driller. These fluids can include, for example, drilling mud, surfactance, brine solutions, thickening solutions, other oil well drilling or completions fluids and the like. In coastal, or other offshore marine environment, the drilling of oil and gas wells employs a platform that can be floating, semi-submersible, fixed, tension leg, spar or the like. Such coastal, offshore or marine oil platforms are well known in the art.
An offshore marine platform typically suffers from lack of space. These special constraints are due to the enormous expense of constructing offshore drilling platforms. A huge array of equipment is needed for the drilling and operation of oil and gas wells. Constant supply and resupply that is an ongoing procedure. Huge work boats carry drill pipe, equipment, personnel, food, drilling fluids, completion fluids, and other material to the offshore platform. Unloading and placement of these supplies is an enormous problem.
In the handling of fluids, huge volumes (with huge weight) can be required, and after they are expended, the tank or other vessel that carried the fluid must quickly be moved from the rig floor to make room for the others.
Over the years, 55 gallon drums and other like disposable containers have been used to transfer drilling and other fluids to and from an oil and gas well drilling rig. These drums and like containers create a huge storage problem for the rig operators.
U.S. Pat. No. 6,915,815 issued Jul. 12, 2005 to Ness for a fluids management system, that patent being hereby incorporated herein by reference.
BRIEF SUMMARY OF THE INVENTION
The present invention provides an improved fluids transfer system that enables a rig operator to efficiently and quickly transfer fluids during normal course of operation of the offshore oil well drilling or production platform.
The present invention provides an efficient and novel system, including a method and apparatus for transferring drilling fluids to an offshore oil and gas well drilling platform and for fluid transfer once on the platform.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
FIG. 1 is a perspective view of the preferred embodiment of the apparatus of the present invention;
FIG. 2 is an elevation view of the preferred embodiment of the apparatus of the present invention;
FIG. 3 is another elevation view of the preferred embodiment of the apparatus of the present invention;
FIG. 4 is a side view of the preferred embodiment of the apparatus of the present invention;
FIG. 5 is a fragmentary perspective view of the preferred embodiment of the apparatus of the present invention;
FIG. 6 is a fragmentary perspective view of the preferred embodiment of the apparatus of the present invention illustrating the piping system;
FIG. 7 is a plan view of the lower module of the preferred embodiment of the apparatus of the present invention;
FIG. 8 is a sectional view taken along lines 8 - 8 of FIG. 3 ;
FIG. 9 is a sectional view taken along lines 9 - 9 of FIG. 7 ;
FIG. 10 is a sectional view taken along lines 10 - 10 of FIG. 7 ;
FIG. 11 is a sectional view taken along lines 11 - 11 of FIG. 7 ;
FIG. 12 is a partial perspective view of the preferred embodiment of the apparatus of the present invention illustrating one of the resupply tanks;
FIG. 13 is a fragmentary elevation view of resupply tank of FIG. 13 ;
FIG. 14 is a plan view of a second embodiment of the apparatus of the present invention;
FIG. 15 is partial plan view of the second embodiment of the apparatus of the present invention;
FIG. 16 is a sectional view taken along lines 16 - 16 of FIG. 14 ;
FIG. 17 is a sectional view taken along lines 17 - 17 of FIG. 14 ;
FIG. 18 is a sectional view taken along lines 18 - 18 of FIG. 14 ;
FIG. 19 is a sectional view taken along lines 19 - 19 of FIG. 14 ;
FIG. 20 is a partial perspective view of the second embodiment of the apparatus of the present invention;
FIG. 21 is a sectional view taken along lines 21 - 21 of FIG. 14 ;
FIG. 22 is a sectional view taken along lines 22 - 22 of FIG. 14 ;
FIG. 23 is a partial, cutaway view of the second embodiment of the apparatus of the present invention;
FIG. 24 is a partial perspective view of the second embodiment of the apparatus of the present invention;
FIG. 25 is a partial plan view of the preferred embodiment of the apparatus of the present invention;
FIG. 26 is a sectional view taken along lines 26 - 26 of FIG. 25 ;
FIG. 27 is a sectional view taken along lines 27 - 27 of FIG. 25 ;
FIG. 28 is a partial perspective view of the preferred embodiment of the apparatus of the present invention; and
FIG. 29 is a partial perspective view of the preferred embodiment of the apparatus of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1-4 show generally the preferred embodiment of the apparatus of the present invention, designated generally by the numeral 10 in FIGS. 1-4 . Fluids management apparatus 10 includes a lower module or storage reservoir 11 and an upper module or resupply reservoir 12 .
The lower module or storage reservoir 11 has a platform deck 13 that carries docking station 14 . The docking station 14 can be centrally located upon platform 13 to provide a deck or walkway 15 that extends along one or more sides of the docking station 14 . Walkway 15 can be provided with suitable railing 16 for protecting workers that ascend stairway 17 to gain access to platform deck 13 and walkway 15 .
The upper module or resupply reservoir 12 can be a liftable structure that can be lifted using a crane or other lifting device so that it can be removed from or placed upon docking station 14 . This upper module or resupply reservoir 12 is provided with one or more resupply tanks 18 . Each tank 18 (see FIGS. 12-13 ) is a fluid containing vessel that has a lower end portion with flow outlet 19 . A piping spool piece 20 is connected to flow outlet 19 (for example, welded thereto) and can include valve 21 for controlling fluid flow from tank 18 during use. In addition to valve 21 , spool piece 20 can be provided with hose coupling fitting 22 or other suitable outlet fitting so that the combination of valve 21 and hose coupling (or other fitting) 22 enables fluid to be discharged from tank 18 as needed. Tank 18 can be provided with a plurality of feet 23 that space the fluid containing portion of tank 18 above an underlying support surface to provide clearance for the attachment of spool piece 20 , valve 21 and hose coupling fitting 22 to flow outlet 19 .
Tank 18 can be of welded steel construction such as stainless steel, for example. Tank 18 can be of any suitable fluid containing material that is compatible with the various oil and gas well drilling fluids that will be transported to the lower module or resupply reservoir 12 . Spool piece 20 , valve 21 and hose coupling fitting 22 are commercially available pipe, valve, and fitting items.
In FIGS. 1-4 resupply reservoir 12 has a reservoir frame 24 that is configured to hold one or more resupply tanks 18 , a pair of tanks 18 being shown contained within reservoir frame 24 in FIGS. 1-4 . In an alternate embodiment ( FIGS. 13-23 ), four resupply tanks are provided. The particular construction of reservoir frame 24 can be seen in co-pending U.S. patent application Ser. No. 10/356,706, filed on Jan. 31, 2003 and incorporate herein by reference.
A piping system 25 (see FIGS. 1-4 , 6 , 7 , and 8 ) is provided for transferring fluids from a selected tank 18 of resupply reservoir 12 to a selected storage tank 34 - 39 that is a part of storage reservoir 11 . The piping system 25 thus provides piping and hoses that are connectable to a selected tank 18 of resupply reservoir 12 and enable a transfer of fluid to a selected one of the tanks 34 - 39 .
In the drawings, the letters A, B, C, D, E, F are used to designate six different fluids that can be handled using the fluids management apparatus 10 and method of the present invention. In FIG. 1 , these different fluid designations A, B, C, D, E, F can be seen as labels 40 , placed upon the wall of storage reservoir 11 above respective storage reservoir outlets 26 , 27 , 28 , 29 , 30 , 31 . During use, these labels 40 could be numbers, letters, or the actual names of the chemicals to be transferred.
In the drawings, the letters A, B, C, D, E, F have been placed in the appropriate location on each of the figures to indicate the particular chemical contained within a particular storage tank 34 - 39 . These letters A, B, C, D, E, F have also been used to mark the different manifolds, pipes and hoses that transfer the selected chemical that is represented by the letter A, B, C, D, E, or F. Following are exemplary chemicals that could be handled using the method and apparatus of the present invention.
Each of the storage reservoir outlets 26 - 31 is provided with a discharge valve 32 and a discharge flow line 33 that can be of any selected length and that can be used to transmit the selected fluid A, B, C, D, E or F to any location on the platform during drilling operations. In FIG. 7 , the storage reservoir or lower module 11 can be seen subdivided (as shown by dotted lines) into six different storage tanks 34 , 35 , 36 , 37 , 38 , 39 . The letters A, B, C, D, E, F in FIG. 7 are placed upon a man-way for each storage tank. Such man-ways enable the tank interiors to be accessed for inspection, cleaning, maintenance and the like. The largest tank 34 has man-way 41 that bears the letter A for the chemical A that is contained within tank 34 . Likewise, the tank 35 has a man-way 42 that bears the letter B indicating that a chemical B is contained within tank 35 .
The additional tanks 36 , 37 , 38 , 39 provide man-ways 43 , 44 , 45 , 46 respectively, each labeled with a letter representing the chemical that is contained within that particular storage tank 36 , 37 , 38 , or 39 . The piping system 25 includes flow lines for enabling a selected fluid to be transmitted from any one of the resupply tanks 18 to any one of the storage tanks 34 - 39 . For example, flow line 47 is a flow line that is provided on deck 13 for transmitting fluid from a selected tank 18 to the first storage tank 34 . Flow line 48 can be used to transmit fluids from a selected resupply tank 18 to tank 35 . Likewise, flow line 49 transfers fluid from a selected resupply tank 18 to tank 36 . Flow line 50 transfers fluid from a selected resupply tank 18 to tank 37 . Flow line 51 transfers fluid from a selected resupply tank 18 to tank 38 . Flow line 52 transfers fluid from a selected resupply tank 18 to tank 39 .
FIGS. 14-24 show a second embodiment of the apparatus of the present invention, designated generally by the numeral 60 . Fluids management apparatus 60 provides an operations reservoir 61 and resupply reservoir 62 . Operations reservoir 61 has a platform deck 63 and provides a docking station 64 that is receptive of resupply reservoir 62 as shown, for example, in FIG. 16 . Walkway 65 is a part of platform deck 63 that surrounds docking station 64 . Railing 66 can be provided at the periphery of walkway 65 as shown in FIG. 14 . A stairway 67 enables users to ascend to platform deck 63 .
Resupply reservoir 62 carries a plurality of preferably four resupply tanks 68 . Each resupply tank 68 has a pair of flow outlets 69 , 70 , each provided with a spool piece that can include a valve. In FIG. 20 , flow outlet 69 communicates with spool piece 71 that includes valve 73 . Spool piece 71 also provides a hose coupling fitting 75 for attaching a flow conveying hose to the spool piece 71 at hose coupling fitting 75 . Similarly, spool piece 72 provides valve 74 and hose coupling fitting 76 . The resupply tank 68 can have a plurality of feet 77 . The plurality of resupply tank 68 are contained within resupply reservoir frame 78 .
Piping system 79 ( FIGS. 14 , 15 , 16 , 17 , 18 and 21 - 22 ) is used to transfer a selected fluid contained in a selected resupply tank 68 to any one of a plurality of selected storage tanks 88 , 89 , 90 , 91 , 92 , 93 (see FIG. 23 ). Each storage tank 88 - 93 has a storage reservoir outlet. In the drawings, the tank 88 has reservoir outlet 80 . The storage tank 89 has reservoir outlet 81 . Similarly, storage tanks 90 , 91 , 92 , 93 communicate respectively with storage reservoir outlets 82 , 83 , 84 , 85 . Each of the storage reservoir outlets 80 - 85 can provide a valve 86 and an outlet fitting 87 .
Labels 94 can be placed above the outlets 80 - 85 or in a selected location next to the selected storage tank 88 - 93 to identify the contents of the storage tank 88 - 93 . Each storage tank 88 - 93 provides a man-way for enabling access to the storage tank interior. In FIG. 14 , tank 88 has man-way 95 . Tank 89 has man-way 96 . Similarly, the tanks 90 , 91 , 92 , 93 provide respective man-way openings 97 , 98 , 99 , 100 .
The piping system 79 provides a plurality of upper level flow lines 101 - 106 . The piping system 79 also provides a plurality of lower level flow lines 107 - 112 . These flow lines 101 - 112 enable a selected fluid contained in any selected resupply tank 68 to be added to any selected storage tank 88 - 93 . By providing the two spool pieces 71 , 72 and related fittings to each supply tank 68 , this fluid transfer can be effective notwithstanding the orientation of a storage tank 68 when it is placed in resupply reservoir frame 78 . A flexible hose 113 can be coupled to a selected spool piece 71 or 72 or a selected resupply tank 68 . That flexible hose 113 can also be connected to any one of the flow lines 101 - 112 depending upon the storage tank 88 - 93 that is to be re-supplied with fluid. Each flow line section 101 - 112 has preferably two (2) inlets 123 for receiving fluid via a hose 113 from a resupply tank 68 . Each flow line section 101 - 112 has at least one discharge 124 for discharging fluid to a selected one of the storage tanks 87 - 93 .
Resupply reservoir frame 78 can be lifted using a crane that is rigged using slings 125 for example to the plurality of lifting eyes 115 at the upper end portion of resupply reservoir frame 78 . Each resupply tank 68 has a plurality of lifting eyes 116 enabling each individual resupply tank 68 to be lifted using a crane or other lifting device that is rigged to the lifting eyes 116 .
A plurality of discharge flow lines 117 , 118 , 119 , 120 , 121 , 122 are provided for discharging fluid from a selected respective storage tank 88 , 89 , 90 , 91 , 92 , 93 .
FIGS. 25-29 illustrate a specially configured base upon which reservoir 11 can be rested for load transfer between the liquids contained in reservoir 11 (and any docked supply reservoir) and a platform or rig.
Base 126 employs base extensions 127 , 128 that are removably connectable to base 126 prior to use. The extensions 127 , 128 can be removed to facilitate transport to or from a well drilling site, platform, rig or the like. Once added to base 126 , extensions 127 , 128 form with base 126 a structural under support that helps reduce load bearing per unit area (e.g. square foot) by forming a new base periphery 149 that is larger than the reservoir periphery 130 .
Arrow 129 in FIG. 28 illustrates the addition of a base extension 127 to base 126 . Bolted connections 148 can be used to secure each extension 127 , 128 to base 126 .
Each extension 127 , 128 comprises at least one elongated longitudinal beam 131 and multiple transverse beams 132 , 133 , 134 . Each transverse beam is fitted with a plate having plate openings 150 that are receptive of bolted connections 148 . End beam 132 has plate 135 . End beam 133 has plate 136 . Beams 134 each have a plate 137 .
Base 126 includes multiple longitudinal beams 138 , 139 , 140 that are connected together with transverse beams 141 , 142 , 143 , 144 to provide therewith a generally rectangular, welded beam network. Base 126 can have a periphery that is equal to or larger than the periphery 130 of reservoir 11 .
Arrow 145 illustrates the placement of reservoir 11 on base 126 . Base extensions 127 , 128 can then be bolted to base 126 using bolted connections 148 . Each end beam 141 , 142 has a plate that has plate openings 150 . End beam 141 has a plate 146 at each of its ends. Likewise, beam 142 has plates 147 at each of its ends. Each short beam 151 has a plate 152 . Upon assembly of an extension 127 or 128 to base 126 , plates 135 and 146 are placed together face to face wherein the openings 150 of the plates 135 , 146 align so that they can be bolted together using bolted connections 148 . In like fashion, plates 137 and 152 are aligned face to face to be bolted together as shown.
The following is a list of parts and materials suitable for use in the present invention.
PARTS LIST
Part
Number
Description
10
fluids management apparatus
11
storage reservoir
12
resupply reservoir
13
platform deck
14
docking station
15
walkway
16
railing
17
stairway
18
resupply tank
19
flow outlet
20
spool piece
21
valve
22
hose coupling fitting
23
foot
24
resupply reservoir frame
25
piping system
26
storage reservoir outlet
27
storage reservoir outlet
28
storage reservoir outlet
29
storage reservoir outlet
30
storage reservoir outlet
31
storage reservoir outlet
32
valve
33
discharge flow line
34
storage tank
35
storage tank
36
storage tank
37
storage tank
38
storage tank
39
storage tank
40
label
41
man-way
42
man-way
43
man-way
44
man-way
45
man-way
46
man-way
47
flow line
48
flow line
49
flow line
50
flow line
51
flow line
52
flow line
60
fluids management apparatus
61
storage reservoir
62
resupply reservoir
63
platform deck
64
docking station
65
walkway
66
railing
67
stairway
68
resupply tank
69
flow outlet
70
flow outlet
71
spool piece
72
spool piece
73
valve
74
valve
75
hose coupling fitting
76
hose coupling fitting
77
foot
78
resupply reservoir frame
79
piping system
80
storage reservoir outlet
81
storage reservoir outlet
82
storage reservoir outlet
83
storage reservoir outlet
84
storage reservoir outlet
85
storage reservoir outlet
86
valve
87
outlet fitting
88
storage tank
89
storage tank
90
storage tank
91
storage tank
92
storage tank
93
storage tank
94
label
95
man-way
96
man-way
97
man-way
98
man-way
99
man-way
100
man-way
101
upper level flow line
102
upper level flow line
103
upper level flow line
104
upper level flow line
105
upper level flow line
106
upper level flow line
107
lower level flow line
108
lower level flow line
109
lower level flow line
110
lower level flow line
111
lower level flow line
112
lower level flow line
113
flexible hose
114
hose coupling fitting
115
lifting eye
116
lifting eye
117
discharge flow line
118
discharge flow line
119
discharge flow line
120
discharge flow line
121
discharge flow line
122
discharge flow line
123
flow line section inlet
124
flow line section discharge
125
lifting sling
126
base
127
base extension
128
base extension
129
arrow
130
reservoir periphery
131
elongated longitudinal beam
132
transverse end beam
133
transverse end beam
134
transverse beam
135
plate
136
plate
137
plate
138
longitudinal beam
139
longitudinal beam
140
longitudinal beam
141
transverse end beam
142
transverse end beam
143
transverse beam
144
transverse beam
145
arrow
146
plate
147
plate
148
bolted connection
149
base periphery
150
plate opening
151
short beam
152
plate
All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A method and apparatus for handling fluids on an oil and gas well drilling platform utilizes detachable peripheral frames to reduce the per square foot load transferred to the platform when reservoirs on the apparatus are filled to (or near) capacity.
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TECHNICAL FIELD
The invention relates to the method and apparatus for a sewage water treatment using the biological activating system with suspended activated sludge in particular for small domestic sewage water treatment plants.
BACKGROUND ART
The biological method of-the sewage water treatment consists in utilizing the activated sludge formed by a mixture of various bacteria and small microorganisms. For its existence, this sludge needs organic substances contained in sewage water which is decomposited and thus cleared by these substances. The activating process is possible only due to a continuous oxidation introduced as a rule by blowing air into the activation tank.
For the sewage water treatment are used partly microorganisms seated firmly on their base in the form of various systems of biological filters and reactors wetted by sewage water, partly activating systems with suspended sludge where the sludge floccules are mixed together with sewage water and with air.
The sewage water treatment plants using the suspended sludge method know hirherto can be devided into systems using a continuous sewage water passage through the activation tank, and to systems using a discontinuous or intermittent passage.
In the continuous sewage water treatment systems, the sewage water is supplied after its coarse pre-treatment to the activation tank and, after a technologically necessitated period needed to its clearing, drained to a separated post-sedimentation tank together with the activated sludge. In this tank, the sludge is finally separated by sedimentation on the cleared water being drained away.
In the system using the discontinuous sewage water passage, the sewage water is supplied after its coarse pre-treatment to the activation tank either immediately or having been re-pumped from the equalizing tank. After the water treatment, the activation process is interrupted, i.e. the aeration and the water mixing, if any in the activation tank are stopped the cleared water being pumped or drawn by gravity to the drainage after the sludge sedimentation. After this, the activation tank is refilled the above described treatment cycle being repeated. Compared with the continuous sewage water treatment method, the post-sedimentation tanks can be omitted the activation one (SBR) being refilled in cycles.
The disadvantage of the above described sewage water activation treatment systems is their difficult utilization for small household treatment plants respecting in particular the demands connected with the treatment plant operation control.
In the activation treatment plants using the continuous sewage water passage, the sludge must be continuously re-pumped from the post-sedimentation tank to the sewage water inflow to the activation tank, As soon as the sludge concentration in this tank exceeds the permitted value, the excessive sludge must be pumped away from the sewage water treatment plant, A skilled operator is required to perform regular measuremants of the sludge concentration in the activation tank and to remove the sludge. In addition to this, a low sewage water inflow would cause an intermittent load of the activation tank. This would be followed by a deteriorated drainage water quality or by a necessity of overdimensioning the activation and the post-sedimentation tanks to obtain the required drainage water parameters.
With respect to a sludge accumulation in the activation tank, the hitherto known small sewage water treatment plants with a continuous water passage are designed either for a high sludge density where the sludge suspension must be maintained using a method with high demands on energy for up to 200 days till the sludge drainage without any interruptions of the water treatment plant function, or they require skilled operators draining regularly the sludge away from the activation tank. Both systems cannot be kept functioning for a longer time period without sewage water inflow due to the sludge autolysis followed by the sludge remowal from the activation process introduced stepwise due to the consumption of activation substances in the activation tank. In this way, the water treatment plant function is substantially affected. The activation sewage water treatment plants with discontinuous water passage (SBR) are earmarked by a relatively sophisticated control systems thus being excessively expensive for their use in low capacity sewage water sources.
DISCLOSURE OF INVENTION
The above stated disadvantages are overcome by a method and apparatus for the sewage water treatment according to the present invention where sewage water is supplied to the equalizing tank and from here drained to the activation one: having been treated, the sewage water is supplied to the sedimentitation tank and, after the sludge sedimentation, to the drainage, The invention is based on an automatic interruption of the activation process after a water volume drop in the equalizing tank below the specified minimum level, which is followed by a drainage of the excessive sludge from the activation tank. If the sewage water level in the equalizing tank is increased in excess of its specified operating value, the sludge re-pumping is terminated the activation process being restarted.
After an interruption of the activation process, it is advantageous to drain the excessive sludge after a properly adjusted time interval only.
The activation sewage water treatment plant as defined by the present invention is formed by an activation tank provided with an air supply and with an overflow to the post-sedimentation tank. In addition this post-sedimentation tank is provided with a pump for re-pumping the sludge from the post-sedimentation tank to the activation one and with a drainage outlet. Before the activation tank is arranged an equalizing tank provided with sewage water inlet as well as with a raw water pump transporting sewage water from the equalizing tank to the activation tank, and with a float switch controlling the minimum and the operating sewage water level in the equalizing tank. This float switch stops the activation process and turns on successively the sludge pump when the sewage water drops under the minimum sewage water level and re-starts the activation process and turns off the sludge pumpe when the sewage water reaches the operating sewage water level.
The above described sewage water treatment plant is earmarked by an effective connection of the design elements characterizing the continuous and the discontinuous water passage system for sewage water treatment.
The advantages of the solution described by the present invention consist in the fact that, with a non-uniform sewage water inlet, the activation and the post-sedimentation tanks are uniformly loaded thus enabling their dimensioning to an average daily sewage water inlet volume. In addition, this enables the use of a fine-bubble activation which is the most advantageous biological sewage water treatment method from the viewpoint of the power consumption and the functional qualities to be used ever for the sewage water sources with minimum possible capacity values. The water treatment plant design described by the present invention enables additionally an increase in the activation tank sewage water level thus increasing the water volume contained herein. In this way, the necessary size of all the sewage -water treatment plant can be substantially reduced.
An outstanding advantage of this arangement is represented by the fact that no skilled plant operators are required due to the automatic sludge drainage from the activation tank as described by the present invention.
Another advantage is the substantial reduction of the daily air blowing time caused by frequent blower function interruptions during insufficient sewage water inlet periods: this reduces the danger of the sludge autolysis that would otherwise be caused by the lack of nutrients in the activation tank. During alternating re-pumping of cleared water from the activation tank to the equalizing tank and vice versa, the necessary nutrients are then supplied to the activation process from the sludge decomposing in the equalizing tank, This enables the operation of the whole water treatment plant for up to approximately 3 months without any sewage water inlet with no deterioration in the equipment treatment ability. This makes the sewage water treatment plant to be extremely suitable for use in leisure objects characterized by an intermittent operation in contradiction to other known types The suppression of the sewage water treatment plant activity after a longer interruption of the sewage water inflow can be supported by a higher setting of the minimum water level in the equalizing tank pulling the float a bit higher thus causing an increase in the re-pumping frequency and, in this way, a reduction of the total blowing time per day. Another possibility is represented by an incorporation of a timing switch into the treatment plant power supply turning the plant on only for a certain number of hours per day.
An important contribution to the environment quality that cannot be neglected is the ability of the activation system described by the present invention to perform a sewage water denitrification including a partial removal of phosphorus in the biological way which was either impossible or considerably complicated in small sewage water treatment plants used hitherto. In this system, the denitrifying action is introduced by interrupting the continuous activation process and by a successive re-pumping of the nitrified sewage water into an anoxical or an anaerobe equalizing tank environment. Successively, a mixture of cleared (denitrified) and raw water is pumped into the activation tank from the equalizing one. In this way, the effectivity of the treatment process is automatically increased by the system depending on the volume of the sewage water inflow. During low inflow period, removal of organic impurities and of nitrogen is provided by nitrification and successive denitrification. With an increase in the sewage water inflow, the number of re-pumping cycles is successively reduced thus lowering the degree of denitrification: a further reduction of the sewage water detention time in the activation tank leads to a successive reduction of the nitrification degree limiting lately the effectivity of the organic impurities removal. With a reduced sewage water inflow, the effectivity of the treatment process is automatically increased up to water denitrification. In this way, the system responds as an entity to the sewage water inflow volume whereby the maximum plant passage is given by the air raw water pump capacity (or by the capacity of another pump used) being designed usually for two or three times as much as the daily average sewage water volume. The most advantageous arrangement is the use of an air-lift pump (the mamoth one) increasing continuously its capacity with the increase in the water level in the equalizing tank and reducing it correspondingly with the decrease in the water level thus extending the total activation period duration till the system switchover.
The sewage water denitrification can be secured always by a proper dimensioning of the water treatment plant tanks in order that minimum water level in the equalizing tank can be reached more frequently during the plant operation thus increasing the frequency of the activation process interrupts.
BRIEF DESCRIPTION OF DRAWINGS
One of the possible implementations of the activation plant described by the present invention is shown in the attached drawings.
FIG. 1 illustrates the ground plan of the water treatment plant,
FIG. 2 contains the vertical section drawing while the principal plant diagram is shown in FIG. 3.
DESCRIPTION OF PREFERRED EMBODIMENT
The activation-type sewage water treatment plant as illustrated by FIG. 1, 2 and FIG. 3 is formed by three functionally independent tanks connected into a single system. They are the equalizing tank 1 with sewage water inlet 5, the activation tank 3 with an air supply, i.e. with the aerating pipe 7 connected to two aerating compressors 10, 11 and with an overflow 19 to the post-sedimentation tank 4 and, finally, the post-sedimentation tank 4 with clear water drainage 6. The equalizing tank 1 is provided with the raw water pump 13 driven by the compressor 9: the pump is used to transport raw or pre-treated water into the activation tank 3. The equalizing tank 1 is further provided with a screen 13a, which permits transfer of raw water to the pump 13. In addition, the plant comprises a water level measuring device, usually a float switch 8 transforming the plant operating mode if the sewage water level in the equalizing tank 1 drops below its minimum setting 15 or exceeds its operation settin 16. The activation tank 3 is provided with sludge pump 14 connected to the sludge pumping compressor 12 used to re-pump the excessive sludge to the equalizing tank 1 up to the sludge level setting 2 in the activation tank 3. The post-sedimentation tank 4 is provided with the sludge recirculation pump 17 connected to the sludge recirculation compressor 18: this pump is used to re-pump the sedimented sludge to the activation tank 3.
Sewage water is supplied to the equalizing tank 1 via the sewage water supply 5. At the same time, the equalizing tank 1 is used to provide the primary sedimentation and to store the excessive sludge re-pumped from the activation tank 3. With a standard operation level in the equalizing tank 1, the sewage water inflow is re-pumped into the activation tank 3. Having been treated in the activation tank 3, the mixture of clear water and activation sludge is supplied to the post-sedimentation tank 4 the cleared water being drained by gravity from the post-sedimentation tank 4 thus leaving the water treatment plant. The sedimented sludge is permanently or intermittently re-pumped to the activation tank 3 by the sludge recirculation pump 17. A limited capacity of the raw water pump 13 helps to reach the condition that even with a non-uniform sewage water supply to the water treatment plant, the hydraulic load of the activation tank 3 as wel as of the post-sedimentation one 4 is uniform.
During the operation of these small household sewage water treatment plants with a non-uniform sewage water supply, the sewage water inflow e.g. at night is low enough so that the water level in the equalizing tank 1 drops below its minimum setting 15. This is the instant when the activation process is disabled by the float swich 8, i.e. the aerating compressors 10, 11 are turned off together with the raw water pump 13 thus puting the activation tank 3 out of operation. The sludge recirculation pump 17 is turned off together with the aeration if the air source for the sludge pump 17 is a common compressor for aerating and for the raw water pump 13 in water treatment plants with higher capacity values. If the sludge recirculation pump 17 is provided with an independent compressor and if the inflow 19 from the activation tank 3 to the post-sedimentation tank 4 is situated closely below the water level in the activation tank 3, the sludge recirculation pump 17 is kept permanently functioning.
At the same time, or better--after a specified time delay enabling the sedimentation of the activated sludge at the bottom of the activation tank 3, the sludge pump 14 is turned on starting to re-pump the contents of the activation tank 3 into the equalizing tank 1. The inflow pipe of the sludge pumpe 14 is placed above the activation tank 3 bottom at the sludge level 2, i.e. In the height of the required sludge layer in the activation tank 3 reached after the sedimentation time. As a rule, the sludge level 2, is set in such a way that the sludge after a 40 minutes sedimentation takes up 1/4 up to 1/3 of the activation tank 3 volume which corresponds to a sludge concentration obtained by mixing of approximately 3 kg dry sludge in 1 m 3 of the activation mixture for a supposed sludge index of ca 80. In this way, the sludge pump 14 removes only the sludge in excess of the sludge level setting 2. The activation delay of the sludge pump 14 is chosen so that the sludge is sedimented at the bottom of the tank 3 before the pumping of the activation tank 3 contents otherwise the necessary sludge quantity in the activation tank 3 would be reduced due to pumping off the mixture of non-sedimented sludge with water if the sludge re-pumping were too frequent. Clear water is pumped off only having pumped off the excessive sludge to the inflow level of the sludge pump 14. As soon as the water level in the equalizing tank 1 reaches its operation setting 16 chosen always to exceed the minimum setting 15, the sludge pump 14 is turned off by the float switch 8 activating at the same time the aerating compressors 10, 11, the raw water pump 13 and, possibly, the sludge recirculation pump 17. The sewage water level in the equalizing tank 1 is increased to its operation setting 16 due to re-pumping a certain portion of the activation tank 3 contents to the equalizing tank 1 or due to the sewage water supply to the equalizing tank 1 or, possibly, due to a combination of both above mentioned causes. The system then continues its activity as a standart sewage water treatment plant with continuous sewage water passage in the equalizing tank 1 below the minimum water level setting 15.
The height of the minimum level setting 15 and that of the operation setting 16 must be chosen with respect to the actual sewage water inflow volume to the water treatment plant, to the amount of, oxygen dissolved in the activation tank 3 depending on the capacity of the aerating compressors 10, 11, and due to the substance load of the sewage water. Another viewpoint may be the requirement concerning the cleared water denitrification.
The start delay of the sludge pump 14 depends on the sludge sedimentation speed and on the depth of the activation tank 3. Its usual values are between 30 and 90 minutes.
The water treatment plant with no requirements concerning the water denitrification is run with an activation tank 3 volume and with an effective equalizing tank 1 volume usually equal to the daily average volume of the sewage water inflow to the water treatment plant. The minimim level setting 15 is chosen so (usually 0,7 m above the bottom of the equalizing tank 1) that the disabling of the aerating and the following sludge draw-off from the activation tank 3 occur approximately once in a day up to once in a week. The difference between the minimum level 15 and its operation value 16 is set to a small value, usually not more than 0,2 m in order to obtain the shortest possible activation interrupt time.
The water treatment plant where water denitrification is required is run with larger volumes of the equalizing tank 1 and of the activation tank 3: these volumes are usually equal to twice as much as the daily average water inflow into the treatment plant. It is necessary to provide a sufficient detention time of the sewage water in the activation tank 3 to obtain complete nitrification with a sufficient volume of the equalizing tank 1 available at the same time between the minimum and maximum levels 15 and 16 respectively to enable re-pumping of the maximum possible cleared water volume from the activation tank 3 to the anoxic environment of the equalizing tank 1 where this water is mixed with raw water and then denitrified. The minimum level 15 is then set to obtain the aeration disabling, the sludge draw-off from the activation tank 3 and the cleared water-re-pumping to the equalizing tank 1 at least once in a day.
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Method for sewage water treatment using suspended activated sludge where sewage water is supplied to the equalizing tank being then re-pumped to the activation tank from which is supplied to the post-sedimentation tank after the clearing process and from here, after the remaining sludge sedimentation, to the drainage. The activation process is automatically interrupted after a drop of the sewage water level in the equalizing tank below the minimum level setting and the excessive sludge is then pumped off from the activation tank. The sludge re-pumping is interrupted and the activation process restored owing to the subsequent raising of the sewage water level in excess of the operation level setting.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No. 13/889,612, filed May 8, 2013 (now U.S. Pat. No. 9,400,065). This is a continuation in part of U.S. patent application Ser. No. 13/296,928, filed Nov. 15, 2011 (now U.S. Pat. No. 9,371,723), which was a non-provisional of U.S. provisional Application Ser. No. 61/414,132, filed Nov. 16, 2010. Each of these applications are incorporated herein by reference and priority of each is hereby claimed.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable
REFERENCE TO A “MICROFICHE APPENDIX”
[0003] Not applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The invention relates generally to the rapid deployment and retrieval of a frac water transfer system used in oil and gas operations, and more particularly, to the rapid deployment and retrieval of a frac water transfer system used for hydraulic fracturing operations.
[0006] 2. General Background
[0007] Hydraulic fracturing is a process used in the oil and gas industry to stimulate the production rate of a well. This process is also known as “fracing,” or conducting a “frac job,” in the industry. Techniques used in hydraulic fracturing generally involve injecting a fluid down a well at a high pressure. The injected fluid fractures the subterranean formation surrounding the well. A proppant may also be added to the fluid to aid in propping the fractures. The fractures create channels through which oil and/or gas can flow, facilitating the flow of the oil and/or gas to the well for production.
[0008] A typical preliminary step in preparing a frac job is transporting a large volume of water (“frac water”) from a water source to a certain destination. The destination may be any receptacle suitable for holding frac water located in the vicinity of where the frac job will be carried out, including, but not limited to, a buffer pit, a frac pit, a frac tank, or a work tank.
BRIEF SUMMARY OF THE INVENTION
[0009] The apparatus of the present invention solves the problems confronted in the art in a simple and straightforward manner.
[0010] One or more embodiments of the invention relate to a system for transferring frac water between a source of the frac water and a frac water destination.
[0011] The system may comprise a subsystem for determining one or more characteristics of the frac water transfer system, and a portable frac water delivery subsystem. The subsystem for determining one or more characteristics of the frac water transfer system may comprise means for measuring one or more terrain parameters between the frac water source and the frac water destination, and means for designing a pipeline to be assembled between the frac water source and the frac water destination.
[0012] The means for designing may receive the one or more terrain parameters as input and generate output data. The output data may be presented as a set of pressure profiles reflecting one or more measurements relating to one or more characteristics of the pipeline to be assembled.
[0013] The portable frac water delivery subsystem may comprise one or more segments of lay flat hose and one or more tracked carriers for transporting the lay flat hose. The one or more segments of the lay flat hose may be connected in series to assemble one or more pipelines for transferring the frac water from the source of the frac water to the frac water destination. Each of the tracked carriers may comprise a lifting subsystem and a tensioning subsystem. The lifting subsystem may be used to load the one or more spools onto the tracked carrier and/or offloading the one or more spools from the tracked carrier. The lifting subsystem may comprise an arm. One or more linkages may connect the arm to the tracked carrier. To control the arm, one or more hydraulic cylinders may be used to move the one or more linkages. The arm may be used to selectively engage the one or more spools. The tensioning subsystem may be used to flatten the one or more segments of the lay flat hose to be wound onto the one or more spool. Further, the tensioning subsystem may be used to substantially remove water from the one or more segments of the lay flat hose. The tensioning subsystem may comprise a drive subsystem for rotating the one or more spools. A plurality of rollers may selectively engage the one or more segments of the lay flat hose onto the one or more spools.
[0014] The one or more segments of the lay flat hose may be routed through the plurality of rollers in an alternating over and under configuration. The system may further comprise one or more conveyance vehicles for transporting equipment between an equipment storage site and the frac water source and/or the frac water destination, the equipment comprising the one or more spools. One or more embodiments of the invention relate to a method of deploying a system for transferring frac water between a source of the frac water and a frac water destination. The method may involve determining one or more characteristics of the frac water transfer system; deploying a portable frac water delivery subsystem; and assembling one or more pipelines for transferring the frac water from the source of the frac water to the frac water destination. Determining one or more characteristics of the frac water transfer system may involve measuring one or more terrain parameters between a water source and a water destination and determining one or more pipeline design parameters. One or more pipelines to be assembled may be designed using a means for designing. The means for designing may receive the one or more terrain parameters and the one or more design parameters as input. The means for designing may further generate output data presented as a set of pressure profiles reflecting one or more measurements relating to one or more characteristics of the pipeline to be assembled.
[0015] The portable frac water delivery subsystem may comprise one or more segments of lay flat hose and one or more tracked carriers for transporting the lay flat hose. Each tracked carrier may comprise a tensioning subsystem for flattening the one or more segments of the lay flat hose to be wound onto one or more spools. The method may further involve conveying one or more spools to the frac water source and/or the frac water destination, the one or more spools wound with the one or more segments of the lay flat hose. The method may further involve loading the spools onto the one or more tracked carriers and/or offloading the one or more spools from the one or more tracked carriers. The tracked carriers may further comprise a lifting subsystem for loading and/or offloading the one or more spools. The lifting subsystem may comprise an arm. One or more linkages may connect the arm to the tracked carrier. To control the arm, one or more hydraulic cylinders may be used to move the one or more linkages. The arm may be used to selectively engage the one or more spools. The method may further involve retrieving the one or more segments of the lay flat hose from the ground. Retrieval may involve selectively engaging the tensioning subsystem with the one or more segments of the lay flat hose. The tensioning subsystem may further comprise a plurality of rollers, and a drive subsystem for rotating the one or more spools. Retrieval may further involve routing the one or more segments of the lay flat hose through the plurality of rollers; winding the one or more segments of the lay flat hose onto the one or more spools; and substantially removing water from the one or more segments of the lay flat hose. Assembling the pipeline may involve connecting a plurality of segments of the lay flat hose in series. The ends of the segments of the lay flat hose may be fitted with sexless, easy to connect couplings. One or more embodiments of the invention may relate to a computer program product. The computer program product may comprise a computer usable medium having computer readable code embodied thereon for determining one or more characteristics of a frac water transfer system. The computer readable program code may comprise computer program code for receiving one or more terrain parameters as input; computer readable program code for receiving one or more design parameters as input; and computer readable code for generating output data based on at least one of: at least one terrain parameter; and at least one design parameter. The one or more terrain parameters may comprise at least one of: distances between adjacent points along a flow path of the frac water transfer system, elevations at points along the flow path, one or more parameters indicative of a degree of obstruction of the flow path; and one or more measurements taken by measurement devices disposed along the flow path, the one or more measurements relating to the one or more characteristics. The one or more design parameters may comprise at least one of: a number of one or more pumps along the flow path, placement locations of the one or more pumps along the flow path, a number of one or more filter pods along the flow path, and placement locations of the one or more filter pods along the flow path.
[0016] The output data may relate to one or more characteristics of the frac water transfer system, including, but not limited to: water hammer or hydraulic shock effects; wave velocity; friction; hydrostatic head; hydraulic force; pressure loss due to friction; and positive pressure needed to overcome friction.
[0017] The computer program product may further comprise computer readable program code for adjusting at least one of: at least one terrain parameter; and at least one design parameter to generate at least one adjusted parameter.
[0018] The at least one adjusted parameter may comprise: an adjustment to at least one of: the one or more parameters indicative of a degree of obstruction of the flow path, the number of pumps, the placement locations of the pumps along the flow path, the number of filter pods, and the placement locations of the filter pods along the flow path. Computer readable program code may receive the at least one adjusted parameter as input and generate updated output data based on the at least one adjusted parameter. The output data may be presented to a user as a set of pressure profiles reflecting one or more measurements relating to the one or more characteristics of the frac water transfer system. The computer program product may further comprise computer readable program code for generating final output data from the updated output data on the condition that at least one characteristic of the frac water transfer system represented by updated output data is within a predetermined range from a desired value of the at least one characteristic.
[0019] Water for use in hydraulic fracturing is often referred to as “frac water”. Frac water may be obtained from one or more sources of water comprising lakes, rivers, ponds, creeks, streams, well water, flow-back water, produced water, treated water and any other source of water. Conventional methods of moving water over long distances involve extensive labor, time and transportation of, among other things, fixed-length pipes, fittings, and pumps.
[0020] One or more embodiments of the present invention relate to a system, method and apparatus for the rapid deployment and retrieval of a frac water transfer system. Embodiments of the system and method of the present invention employ one or more flexible, lay flat hoses and/or one or more segments of lay flat hose for the transfer of frac water over long distances. In one embodiment, a computer program product is provided.
[0021] The lay flat hose may be collapsible such that it may lay flat when substantially empty (i.e. substantially devoid of water or other matter). Thus, the lay flat hose can be wound onto spools, folded into flaking boxes, or otherwise stored in a compact manner. Because the hose is very flexible and conforms to the terrain upon which it is laid, 90°, 45°, 22.5°, or other elbow fittings would not be required in order to have a pipeline containing turns. Characteristics of fluid flow in a pipe such as working pressure, burst pressure, maximum efficiency rate, and maximum feasible rate are considerably higher and thus more desirable for the lay flat hose than for pipes used in conventional methods for frac water transportation.
[0022] The lay flat hose may require fewer connections and pumps than the pipes used in conventional methods for frac water transportation to achieve the desired characteristics during frac water transfer. Moreover, the lay flat hose is difficult to damage, having a life expectancy of approximately five years, whereas the pipes used in conventional methods for frac water transportation have a life expectancy of approximately 2 years.
[0023] In one conventional method, thirty foot (30′) long segments of aluminum piping with an outer diameter often inches (10″) are connected in series to form a pipeline for transporting water over a long distance. A mile of straight piping (i.e., piping containing no turns) may require approximately 176 connections. Clamp type connections are typically used to join the pipes. For pipelines containing turns, 90°, 45°, 22.5°, or other elbow fittings may be required. Water may potentially leak through each connection or fitting, thereby decreasing the efficiency of the pipeline and wasting water. The working pressure of the aluminum piping may be approximately 80 psi and the burst pressure may be approximately 150 psi. The maximum efficiency rate may be less than 50 bpm and the maximum feasible rate may be approximately 75 bpm.
[0024] In another conventional method, 3200 ft. or 500 ft. long segments of polyethylene piping with an outer diameter of 4 in. or 6 in., respectively, are connected in series to form a pipeline for transporting water over a long distance. Pipelines having these specifications transfer water at low rates and therefore may not be viable for real-time water transfer.
[0025] In yet another conventional method, 30 ft. long segments of polyethylene piping with an outer diameter of 12 in. are connected in series to form a pipeline for transporting water over a long distance. A mile of straight piping may require approximately 176 connections. Water may potentially leak through each connection, thereby decreasing the efficiency of the pipeline and wasting water. For pipelines containing turns, 90°, 45°, 22.5°, or other elbow fittings may be required. The working pressure of the polyethylene piping may be approximately 150 psi and the burst pressure may be approximately 317 psi.
[0026] The maximum efficiency rate may be approximately 76 bpm and the maximum feasible rate may be approximately 92 bpm. Weighing approximately 26 lbs/ft., manual handling of the polyethylene piping segments is impractical. In one or more embodiments of the invention, a lay flat hose may be deployed in segments ranging from about 5 ft. long to about 700 ft. long and have a nominal inner diameter ranging from about 3 in. to about 16 in. In one or more embodiments, the lay flat hose is deployed in 500 ft. long segments with a nominal inner diameter of 12 in. A straight mile of pipeline constructed out of the lay flat hose may require approximately 11 connections.
[0027] Because the hose is flexible and conforms to the terrain upon which it is laid, elbow fittings, which are prone to leaking, would not be required for pipelines containing turns. The working pressure of the lay flat hose may be approximately 175 psi and the burst pressure may be approximately 400 psi. The maximum efficiency rate may be approximately 100 bpm and the maximum feasible rate may be approximately 130 bpm. The lay flat hose is made of circular woven high tenacity polyester. An elastomeric polyurethane cover and lining completely encapsulate the polyester. A variety of other types of lay flat hose may also be available at a range of sizes, materials, and capabilities. Any lay flat hose suitable for the rapid deployment and retrieval of a frac water transfer system may be used in embodiments of the present invention.
[0028] One or more embodiments of the invention are directed to a computer program product for use in connection with the design and deployment of frac water transfer systems in accordance with embodiments of the invention. The computer program product may generate output data that includes measurements of frac water flow characteristics and/or pressure characteristics determined based on various input parameters. The output data generated by the computer program product may be utilized in making design and equipment choice/placement decisions in connection with the deployment of frac water transfer systems according to embodiments of the invention. The computer program product may comprise a computer usable medium having computer readable program code embodied therein. The computer readable program code may comprise computer readable code for receiving as input one or more terrain parameters. The terrain parameters may include, but are not limited to, distances between adjacent discrete points along the flow path of the frac water from the source to the destination as well as elevations at discrete points along the path. The discrete points between which distance measurements may be taken and/or the discrete points at which elevation measurements may be taken may coincide with the endpoints of segments of the flexible hose. Alternatively, the distance and elevation measurements may be taken continuously at any one or more points along the path traversed by the flexible hose when deployed.
[0029] A manual survey of the terrain may be performed to determine the distance and elevation parameters. Alternatively, or in conjunction with the manual survey, a global positioning system (GPS) device may be employed to precisely measure distances and elevation differences between discrete points along the path. The GPS device may also be used to take continuous distance and elevation measurements along the flow path. In addition to the distance and elevation measurements, the terrain parameters may also comprise one or more parameters indicative of a degree of obstruction at one or more discrete points along the path of the flexible hose. More specifically, the one or more parameters indicative of a degree of obstruction may represent a measure of the degree to which terrain characteristics may obstruct frac water flow through the flexible hose at one or more points along the flow path.
[0030] The distance, elevation, and obstruction parameters, along with any other terrain parameters that may be determined, may together provide a comprehensive survey of the terrain. The computer readable program code may further comprise computer readable program code for receiving as input one or more design parameters. Design parameters may include a number of and/or locations along the frac water flow path at which one or more pumps and/or one or more filter pods may be placed. Adjustments to the number and/or placement of pumps and filter pods may affect frac water flow rates and pressure and flow characteristics at various points along the flow path.
[0031] The computer program product may take as inputs one or more of the terrain and/or design parameters noted above and generate output data relating to one or more of the following pressure/flow characteristics: water hammer or hydraulic shock effects, wave velocity, friction, hydrostatic head, hydraulic force, pressure loss due to friction, positive pressure needed to overcome friction, or any combination thereof.
[0032] However, it should be noted that the above list is not exhaustive and the output data may include any other suitable measurement for assisting in the design, implementation, and deployment of a frac water transfer system according to embodiments of the invention. In order to generate the output data, the computer program product may also receive, as input, data provided by various measurement devices disposed along the frac water flow path correspondingly to the points between which and at which distance and elevation measurements are taken.
[0033] The output data may be provided in the form of a set of pressure profiles reflecting any one or more of the measurements discussed above taken at discrete or continuous points along the frac water flow path. If the pressure and flow measurements provided by way of the pressure profiles do not conform to desired values, one or more parameters may be adjusted and new output data based on the adjusted parameters may be generated. This process may be performed iteratively until the desired pressure and flow characteristics are achieved. More specifically, the path of the flexible hose pipeline from source to destination as well as the location and/or number of pumps and/or filter pods may be determined through an assessment of the output data generated by the computer program product based on iterative adjustments to the input parameters.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0034] For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
[0035] FIG. 1 is a front perspective view of a preferred embodiment for a layout and take up vehicle taken from the driver side;
[0036] FIG. 2 is a front perspective view of the vehicle of FIG. 1 taken from the non-driver side;
[0037] FIG. 3 is a rear perspective view of the vehicle of FIG. 1 taken from the non-driver side;
[0038] FIG. 4 is a rear perspective view of the vehicle of FIG. 1 taken from the driver side;
[0039] FIG. 5 is a side view of the vehicle of FIG. 1 taken from the non-driver side;
[0040] FIG. 6 is a front view of the vehicle of FIG. 1 ;
[0041] FIG. 7 is a top view of the vehicle of FIG. 1 ;
[0042] FIG. 8 is a side view of the vehicle of FIG. 1 taken from the driver side;
[0043] FIG. 9 is a sectional view of the vehicle through the lines 9 - 9 of FIG. 8 ;
[0044] FIG. 10 is a perspective view of a portion of the take up tensioning system;
[0045] FIG. 11 is an exploded perspective view of the portion of the take up tensioning system shown in FIG. 10 ;
[0046] FIG. 12 is a perspective view of the articulating roller of the tensioning system.
[0047] FIG. 13 is an exploded perspective view of the articulating roller of the tensioning system.
[0048] FIG. 14 is a perspective view of the reel lifting system.
[0049] FIG. 15 is a perspective view of a hydraulic cylinder powering the reel lifting system.
[0050] FIG. 16 is a perspective view of the two expanding and retracting articulating arms of the reel lifting system.
[0051] FIG. 17 is a perspective view of one of the arms.
[0052] FIG. 18 is a perspective view of the arm of FIG. 17 broken open to show the hydraulic cylinder which expands and retracts the arm.
[0053] FIG. 19 is a perspective view of the reel rotating and tensioning system.
[0054] FIG. 20 is a perspective view of the reel rotating and tensioning system shown from the opposite side as FIG. 19 .
[0055] FIG. 21 is a perspective view of the motor powering the reel rotating and tensioning system.
[0056] FIG. 22 is a perspective view of the motor powering the reel rotating and tensioning system taken from the opposite side as FIG. 21 .
[0057] FIG. 23 is an exploded perspective view of the sliding connection between the reel rotating and tensioning system of FIG. 21 and the reel.
[0058] FIG. 24 is a perspective view of a reel rotatably connected to a support base.
[0059] FIG. 25 is a perspective view of a bearing that rotatably connects the reel to the base.
[0060] FIG. 26 is a side view of the reel of FIG. 24 .
[0061] FIG. 27 is a rear view of the reel of FIG. 24 .
[0062] FIG. 28 is side view of a reel loading with a lay flat hose.
[0063] FIG. 29 is a side view of the reel lifting system of the vehicle about to pick up a reel.
[0064] FIG. 30 is a perspective view of the reel lifting system of the vehicle about to pick up a reel from the ground.
[0065] FIG. 31 is an enlarged perspective view of a connection between the reel lifting system and the reel.
[0066] FIGS. 32 and 33A are rear views of the reel lifting system of the vehicle about to pick up a reel from the ground.
[0067] FIG. 33B is an enlarged view of a connection between the reel lifting system and the reel.
[0068] FIG. 34 is a perspective view of the reel lifting system of the vehicle in mid path when loading a reel.
[0069] FIG. 35 is a perspective view of the reel lifting system of the vehicle placing the reel on the deck of the vehicle.
[0070] FIG. 36 is a perspective view of the reel lifting system of the vehicle about to pick up a reel from a raised area such as a trailer.
[0071] FIG. 37 is a perspective view of the reel lifting system of the vehicle in mid path when loading a reel.
[0072] FIG. 38 is a perspective view of the reel lifting system of the vehicle placing the reel on the deck of the vehicle.
[0073] FIG. 39 is an enlarged perspective view of the connection between the reel driver and the reel after the reel has been placed on the vehicle.
[0074] FIG. 40 is front perspective view from the non-driver side of the vehicle of FIG. 1 shown with a loaded reel.
[0075] FIG. 41 is rear perspective view from the non-driver side of the vehicle of FIG. 1 shown with a loaded reel.
[0076] FIG. 42 is front perspective view from the driver side of the vehicle of FIG. 1 shown with a loaded reel.
[0077] FIG. 43 is rear perspective view from the driver side of the vehicle of FIG. 1 shown with a loaded reel.
[0078] FIG. 44 is a side view of the vehicle of FIG. 1 shown laying out hose from a reel.
[0079] FIG. 45 is a rear perspective view of the vehicle of FIG. 1 taken from the non-driver side shown laying out hose from a reel.
[0080] FIG. 46 is a rear perspective view of the vehicle of FIG. 1 taken from the driver side shown laying out hose from a reel.
[0081] FIG. 47 is a front perspective view of the vehicle of FIG. 1 taken from the non-driver side showing the taking of hose from the ground.
[0082] FIG. 48 is a side view of the vehicle of FIG. 1 showing the taking up of hose from the ground.
[0083] FIG. 49 is a front perspective view of the vehicle of FIG. 1 taken from the driver side showing the taking up of a hose from the ground.
[0084] FIG. 50 is an enlarged view of the tensioning system used during take up with the articulating roller being in an up position.
[0085] FIG. 51 is a schematic diagram of one embodiment of the method incorporating the vehicle of FIG. 1 .
[0086] FIG. 52 is a front perspective view of the vehicle of FIG. 1 taken from the non-driver side and showing the reel locking system.
[0087] FIG. 53 is a front perspective view of the vehicle of FIG. 52 with a reel loaded on the vehicle and the reel locking system in an unlocked state.
[0088] FIG. 54 is an enlarged perspective view of the reel locking system shown in FIG. 53 .
[0089] FIG. 55 is a front perspective view of the vehicle of FIG. 52 with a reel loaded on the vehicle and the reel locking system in an locked state.
[0090] FIG. 56 is an enlarged perspective view of the reel locking system shown in FIG. 55 .
DETAILED DESCRIPTION OF THE INVENTION
[0091] In one embodiment is provided a system 200 for rapidly deploying a frac water transfer system, as depicted schematically in FIG. 2 . The system 200 comprises one or more segments of lay flat hose 304 wound onto one or more spools or reels 202 .
[0092] The spools 300 comprise a cylindrical core and two sidewalls having a circular cross section. In one or more embodiments, the sidewalls of the spools 300 may comprise spokes 302 , as illustrated in FIGS. 24-28 . Each sidewall further comprises a circumferential surface.
[0093] The lay flat hose 304 may be manually wound onto the spools 202 . The lay flat hose 304 may comprise a first end 306 and a second end 312 . The second end 312 of the lay flat hose 304 is attached to the cylindrical core or drum 308 of the spool 302 such that the end 312 will rotate along with and at substantially the same rate as the drum 308 of the spool 300 .
[0094] In various embodiments, each end 306 , 312 of the lay flat hose segment 304 comprises a coupling 310 . While the coupling 310 of the second end 312 may be disposed proximate the outer surface of the drum 308 , and the lay flat hose 304 may be wound around both the drum 308 and the coupling 310 , such an arrangement may create an irregular shaped spooling resembling an egg. To avoid the irregular shape, the coupling 310 of the second end 312 may be disposed within the drum 308 (see FIG. 28 ). Disposing the coupling 310 within the drum 308 further connects and anchors the second end 312 to the spool 300 .
[0095] In one embodiment, a crank (not shown) that rotates the drum 308 of the spool 300 (or it may be turned manually), thereby rotating and winding the lay flat hose 304 around the drum 308 of the spool 300 . Manual adjustments in alignment of the lay flat hose 304 may be necessary to reduce tangling and ensure that the desired length of lay flat hose 304 fits within the spool's 300 carrying capacity. The number of spools 300 , 300 ′, 300 ″, etc. necessary depends on the desired or required total length of lay flat hose 304 , which is determined, in part, by surveying the path from the water source 208 to the destination 210 .
Reel Drive System
[0096] In various embodiments a drive system 502 may be used to facilitate winding the segments of lay flat hose 304 onto the spools 300 during take up of lay flat hose 304 . For example, drive system 502 may comprise a shaft fitted with friction rollers. The friction rollers may be spaced such that each friction roller aligns with and engages a circumferential surface of a sidewall of the spool 300 . A power source in communication with a motor may rotate the shaft, and consequently rotate the friction rollers, in one direction, causing the spool 300 to rotate in the opposite direction. The drive system may thus replace the manual crank system described above for winding the segments of lay flat hose 304 onto the spools 300 .
[0097] FIG. 19 is a perspective view of the reel rotating and tensioning system 502 . FIG. 20 is a perspective view of the reel rotating and tensioning system 502 shown from the opposite side as FIG. 19 . FIG. 21 is a perspective view of the motor 511 powering the reel rotating and tensioning system 502 . FIG. 22 is a perspective view of the motor 511 powering the reel rotating and tensioning system taken from the opposite side as FIG. 21 . FIG. 23 is an exploded perspective view of the sliding connection between the reel rotating and tensioning system of FIG. 21 and the reel.
[0098] An axle drive subsystem 502 of the crawler 212 may comprise a drive shaft 504 that engages a connection 330 of the spool 300 . The opposing end of the drive shaft 504 that does not engage the spool connection 330 may be fitted with a second gear 510 (driven gear). The second gear's 510 rotation correspondingly rotates the connection 330 and the spool 300 in the same direction.
[0099] A first gear 508 (drive gear) may be substantially aligned in a parallel configuration with the second gear 510 . A motor 511 may be used to rotate the first gear 508 . The teeth of the gears 508 , 510 may mesh in order to transmit the motor's torque. Alternatively, the second gear 510 may be spaced apart from the first gear 508 and a chain 512 may be used to transmit rotary motion from the first gear 508 to the second gear 510 . Guard 513 can cover gears 508 , 510 and chain 512 . Unlike the meshing configuration in which the gears 508 , 510 rotate in opposite directions, the drive chain transmits rotary motion such that the gears 508 , 510 rotate in the same direction. Because the second gear's 510 rotation correspondingly rotates the spool 300 in the same direction, spool 300 rotates in the same direction as the second gear 510 and motor 511 . Rotation of spool 300 in one direction may lay flat hose 304 , and rotation of spool 300 in the opposite direction may take up or retrieve lay flat hose 304 .
[0100] A detachable connection can be made between reel 300 and axle drive subsystem 502 . FIG. 23 is an exploded perspective view of the sliding connection 520 between the reel rotating and tensioning system 502 and the reel 300 . This slidable connection 520 can include first end 522 and second end 524 having first section 530 which accepts telescoping second section 540 . Arrows 590 schematically indicate the ability of first section 530 to slide relative to second section 540 , however, first and second sections are rotationally locked relative to each other so that rotation of second section causes rotation of first section 530 . First end 522 can be coupled to drive axle 504 of subsystem 502 . Second end 524 can be coupled to spool 300 . Spool 300 can rotate relative to its support base 350 . When connected by second end 524 , rotation of telescoping connection 520 causes rotation of spool 300 relative to base 350 .
Tensioning System for Hose Reel
[0101] A tensioning subsystem 602 is provided for the crawler 212 in accordance with various embodiments of the invention. The tensioning subsystem 602 may comprise a plurality of rollers 603 , 604 , 605 (see FIGS. 1-13 and 47-50 ). The lay flat hose 304 may engage the rollers 603 , 604 , and 605 in an alternating over-and-under configuration.
[0102] The second end 312 of the lay flat hose 304 may be connected to the spool 300 so that the lay flat hose may be retrieved. The axle drive subsystem 502 , described above with reference to FIG. 5 , may rotate the spool 300 in either direction to retrieve and wind the lay flat hose 304 onto the spool 300 .
[0103] As the lay flat hose 304 passes through the rollers 603 , 604 , and 605 of the tensioning subsystem 602 , rotational forces on reel 300 from axial shaft 506 cause tensile forces to act upon the lay flat hose 304 , flattening the lay flat hose 304 and ensuring that it is neatly and tightly wound onto the spool 300 . Further, because the tensioning subsystem 602 flattens the lay flat hose 304 , fluid is thereby squeezed out and removed from the lay flat hose 304 . This water removing effect may efficiently dry the lay flat hose 304 and allows it to be readily deployed for further use or stored for later use. In various embodiments, the rollers 603 , 604 , and 605 of the tensioning subsystem 602 may be disposed towards the front of the crawler 212 to facilitate retrieval or take up of the lay flat hose 304 while the crawler 212 is moving in a forward direction.
[0104] The rollers 603 , 604 , and 605 may be disposed at a height above the ground sufficient to vertically lift the lay flat hose 304 off the ground to reduce any wear and tear of the lay flat hose 304 that may otherwise occur by its scraping against the ground during retrieval along with also facilitating removal of water from the vertically lifted portion of the lay flat hose.
[0105] In various embodiments, the tensioning subsystem 602 may comprise one roller 604 (see FIG. 40 ) or two rollers 603 , 604 .
[0106] The rollers 603 , 604 , and 605 may be closely spaced and have parallel axes. The axes of the rollers 603 , 604 , and 605 may also be parallel to the axis 301 of the spool 300 . The rollers 603 , 604 , and 605 may be aligned laterally with respect to each other and the spool 300 such that, when the lay flat hose 304 is retrieved, the lay flat hose 304 is pulled longitudinally towards the spool 300 and wound onto the spool 300 .
[0107] Middle roller 604 may be pivotally connected to support structure 606 . As shown in FIGS. 10-13 , middle roller 604 can have a handle 609 to facilitate selective pivoting of roller 604 relative to rollers 603 and 605 .
[0108] The first end 306 of the lay flat hose segment 304 is the end that is first unwound and offloaded from the spool 300 as the spool 300 is rotated by the axial drive subsystem 502 . The second end 312 of the lay flat hose 304 is the end that is last unwound and offloaded from the spool 300 . The lay flat hose segment 304 may be manually positioned as it unwinds from the spool 300 to ensure placement of the lay flat hose segment 304 suitable for connecting the first end 306 of the lay flat hose segment to the second end 312 of the previously laid lay flat hose segment 304 .
[0109] In various embodiments, the spools 300 of lay flat hose 304 may be provided with one or more support structures, frames, or “skids” 350 . The skids 350 allow for a completely self-contained modular system comprising one or more spools 300 of lay flat hose 304 . Each skid or frame or support 350 may further comprise one or more legs for maintaining the skids in a position suitable for facilitating the loading and offloading of the spools 300 onto and from the skids. Moreover, the legs may facilitate the loading and offloading of the skids 350 onto and from a vehicle or a trailer towed by a vehicle. Each skid or frame or support 350 may further comprise a lifting mechanism allowing for the skid or frame to be self-supported.
[0000] Getting Reels to and/or from Stages Locations/Pre-Staging Reels for Layout or Take Up
[0110] The spools 300 (or combination of spool 300 and base 350 ) may be pre-staged at predetermined positions at which lay flat hose 304 will be needed between the one or more water sources 208 and the one or more destinations 210 to avoid deadheading. The pre-staging positions may be determined based on the terrain parameters gathered from the survey and the output data of the computer program product 224 .
[0111] The skids or frames 350 may be loaded onto one or more conveyance vehicles 204 . Any type of conveyance vehicle 204 suitable for carrying skids or heavy equipment may be used, including, but not limited to: a rollback trailer with a hydraulic lift, a flatbed trailer with a portable forklift, or a flatbed trailer with a knuckle-boom crane. The skids or frames may be lifted and loaded onto the conveyance vehicle 204 manually or with the aid of machinery suitable for lifting heavy equipment. For example, a forklift or a crane may be used to lift the skids onto the conveyance vehicle 204 . In one or more embodiments of the present invention, the spools 300 may be loaded directly onto the conveyance vehicle 204 without the use of skids. It is to be understood that the present invention envisions the conveyance of modules of multiple spools 300 loaded onto skids and/or spools 300 without skids. The conveyance vehicle 204 onto which spools 300 are loaded may be a 48 ft. flatbed trailer with the capacity to carry about 14 spools 300 , approximately 1.25 mi. of lay flat hose 304 . The use of a flatbed trailer may comply with Department of Transportation (DOT) size and weight requirements. The use of a flatbed trailer as the conveyance vehicle 204 facilitates the use of a third party contractor for hauling of the load, which reduces the DOT risk exposure of the person or entity hiring the third party contractor. A desired number of spools 300 may be loaded onto the conveyance vehicle 204 . The desired number of spools 300 is determined, in part, based on the total length of lay flat hose 304 needed to complete the designed pipeline 216 and on the conveyance vehicle's 204 carrying capacity.
[0112] The conveyance vehicle 204 may be driven from the equipment site 206 to the water source 208 to begin laying the lay flat hose 304 towards the frac water destination 210 , i.e., the location to which water will be transported. The frac water destination 210 may be in the vicinity of the location where the frac job will be performed. Alternatively, the conveyance vehicle 204 may be driven to the destination 210 , and the lay flat hose 304 may be laid towards the water source 208 . Besides spools 300 , the conveyance vehicle 204 may carry smaller off-road vehicles 212 and/or various other types of equipment 214 that facilitate the rapid deployment and retrieval of a frac water transfer system in accordance with embodiments of the invention. One or more conveyance vehicles 204 and/or off-road vehicles 212 may be used to transport additional spools 300 of lay flat hose 304 or other equipment 214 , if necessary, to the current pipeline 216 work location.
[0113] The current pipeline 216 work location is defined herein as the vicinity of the location at which the last segment of lay flat hose 304 has been laid. The spools 300 may be offloaded from the conveyance vehicle 204 in a manner similar to that used in loading the skids onto the conveyance vehicle 204 . However, a different manner of offloading the spools 300 from the conveyance vehicle 204 may be used. For example, if a forklift was used to lift and load the spools 300 onto the conveyance vehicle 204 , a forklift may also be used to lift and offload the spools 300 from the conveyance vehicle 204 . But the spools 300 may also be offloaded manually or with the aid of any other machinery suitable for lifting heavy equipment.
[0114] In one or more embodiments, smaller off-road vehicles 212 (see FIGS. 1-15 ) may be used to transport the spools 300 from the conveyance vehicle 204 to the current pipeline work location. The off-road vehicle(s) 212 may be one or more all-terrain vehicles (ATVs), each towing a trailer capable of being towed in an all-terrain environment. The vehicles 212 may position the trailer proximate a spool such that the lifting mechanism on the vehicles 212 is capable of lifting and offloading a spool 300 and lifting and loading the spool 300 onto the trailer. A vehicle (or vehicles) 212 can be positioned near work location 216 as can be a trailer carrying spools 300 .
[0000] Laying Out Hose from Vehicle
[0115] The segment of lay flat hose 304 to be laid may be unwound from the spool 300 . The trailer on which the spool 300 is sitting may comprise a friction roller drive mechanism (not shown) for unwinding the lay flat hose 304 from the spool 300 . A shaft comprising mounted friction rollers may be in contact with the circumferential surface of the sidewalls of the spool 300 . A remote hydraulic power pack may provide the source of power to rotate the shaft, thus rotating the friction rollers in the same direction. The friction rollers may comprise an outside contact surface made of a material having a high coefficient of friction. The contact of the rotating friction rollers with the circumferential surfaces of the sidewalls of the spool 300 in turn causes the spool 300 to rotate in the direction opposite of that in which the friction rollers (and correspondingly, the shaft) are rotating. As the spool 300 rotates, the lay flat hose 304 may be unwound and offloaded from the spool 300 . In one or more embodiments, the drive mechanism may unwind the lay flat hose 304 from the spools 300 at a rate ranging from about 1 mph to about 4 mph.
[0116] FIG. 44 is a side view of vehicle 212 shown laying out hose 304 from a reel 300 . In this figure it is shown that hose 304 is being laid out from the rear or second end 1010 of vehicle 212 . FIG. 45 is a rear perspective view of vehicle 212 taken from the non-driver side shown laying out hose 304 from reel 300 . FIG. 46 is a rear perspective view of vehicle 212 taken from the driver side shown laying out hose from a reel.
[0117] As section 314 of hose lays on the ground and vehicle 212 moves in the direction of arrow 900 hose 304 is impart torsional forces on reel 300 causing reel 300 to tend to rotate in the direction of arrow 920 . During this process drive axle subsystem 502 is coupled to reel 300 , and motor 511 can provide a braking action against free spinning of reel 300 . Depending on the speed of vehicle 212 in the direction of arrow 900 , operator can selectively control the rate of rotation of axle drive subsystem 502 (and thereby reel 304 ) to prevent over-spinning of reel 300 and allowing the flat laying of lay flat hose 304 in the direction of arrow 910 .
Taking Up Previously Layed Out Hose
[0118] FIG. 47 is a front perspective view of vehicle 212 taken from the non-driver side showing the taking up of hose 304 from the ground. FIG. 48 is a side view of vehicle 212 showing the taking up of hose 304 from the ground. FIG. 49 is a front perspective view of vehicle 212 taken from the driver side showing the taking up of hose 304 from the ground.
[0119] As section 314 of hose is taken up from the ground and vehicle 212 moves in the direction of arrow 900 axle drive subsystem 502 imparts torsional forces on reel 300 causing reel 300 to tend to rotate in the direction of arrow 940 . During this process drive axle subsystem 502 is coupled to reel 300 , and motor 511 can over-rotate reel 300 to maintain tension in hose 318 and assist in removal of water from section 317 of hose being taken up. Depending on the speed of vehicle 212 in the direction of arrow 900 , operator can selectively control the rate of rotation of axle drive subsystem 502 (and thereby reel 304 ) to maintain over rotation of reel 300 and tension in hose section 318 , and pick up hose section in the direction of arrow 950 and allowing a dewatered and flat section of lay flat hose 304 to be wound onto reel 300 .
[0120] During the take up process tensioning subsystem 602 comprising plurality of rollers 603 , 604 , 605 engages lay flat hose 304 in an alternating over-and-under configuration (arrows 690 , 692 , and 694 schematically indicate such over and under engagement). As the lay flat hose 304 passes through the rollers 603 , 604 , and 605 of the tensioning subsystem 602 , rotational forces on reel 300 from axial shaft 506 cause tensile forces to act upon the lay flat hose 304 , flattening the lay flat hose 304 and ensuring that it is neatly and tightly wound onto the spool 300 . Further, because the tensioning subsystem 602 flattens the lay flat hose 304 , fluid is thereby squeezed out and removed from the lay flat hose 304 . This water removing effect may efficiently dry the lay flat hose 304 and allows it to be readily deployed for further use or stored for later use. In various embodiments, the rollers 603 , 604 , and 605 of the tensioning subsystem 602 may be disposed towards the front of the crawler 212 to facilitate retrieval or take up of the lay flat hose 304 while the crawler 212 is moving in a forward direction.
[0121] The rollers 603 , 604 , and 605 may be disposed at a height above the ground sufficient to vertically lift the lay flat hose 304 off the ground to reduce any wear and tear of the lay flat hose 304 that may otherwise occur by its scraping against the ground during retrieval along with also facilitating removal of water from the vertically lifted portion of the lay flat hose.
[0122] As shown in FIGS. 49 and 50 , middle roller 604 may be pivotally connected to support structure 606 . As shown in FIGS. 10-13 , middle roller 604 can have a handle 609 to facilitate selective pivoting of roller 604 relative to rollers 603 and 605 . Pivoting middle roller 604 allows end coupling 310 to pass through tensioning system 602 .
Vehicle
[0123] Vehicle(s) 400 may be tracked carriers or “crawlers” 212 as illustrated in FIGS. 1-15 . Vehicle 212 can provide an under carriage or tracked chassis 213 that enables the vehicle 212 to travel over the terrain where the pipeline 216 is to be placed. The vehicle 212 may have deck or bed 402 , a lifting subsystem 404 , a drive axle subsystem 502 , and a tensioning subsystem 602 . The crawler 212 may be designed to be small enough for maneuverability in tight spaces, but yet large enough to optimize the number of trips required to deploy the lay flat hose 304 and to optimize the time required to complete the trips.
[0124] In one or more embodiments, the crawler 212 may have a full length ranging from about 12 ft. to about 15 ft., a full width ranging from about 5 ft. to about 7 ft., and a carrying capacity of over 7,000 lbs. Powered by an engine having between about 70 hp to about 80 hp or more, the crawler 212 may travel at a maximum speed ranging from about 4 mph to about 8 mph or higher. A driver-operator of the crawler 212 may be seated in a location relative to the bed or deck 402 such that the lay flat hose 304 may be laid along the pipeline path 216 without obstructing the driver-operator's forward view. The bed 402 may be designed to provide a stable support structure for at least the spool 300 , the lay flat hose 304 , and the spool's base 406 .
[0000] Loading and Unloading Reels to and/or from Deck of Vehicle
[0125] FIGS. 1-10 and 14-18 illustrate the lifting subsystem 404 of the crawler 212 in accordance with various embodiments of the invention. The lifting subsystem 404 may comprise any mechanism capable of lifting the spool 300 (or the combination of spool 300 and base 406 ) and placing it on the deck or bed 402 of the crawler 212 .
[0126] In various embodiments, the lifting subsystem 404 comprises one or more arms 408 , 409 . An operator may control the movement of the arms 408 , 409 via hydraulic cylinders 414 , 415 . The lift system 404 provides a pair of spaced apart arms 408 , 409 . Each arm is pivotally attached to chassis 213 . Arm 408 is attached to chassis 213 at pivotal connection 416 . Arm 409 is attached to chassis 213 at pivotal connection 417 . Hydraulic cylinders 414 , 415 are provided for raising or lowering arms 408 , 409 . Each cylinder 414 , 415 has an extendable portion or pushrod. Cylinder 414 has extendable pushrod 422 . Cylinder 415 has extendable pushrod 423 . Each arm 408 , 409 can be a telescoping arm, providing an extendable section. Arm 408 can telescope and lengthen by extending section 420 . Arm 409 can telescope and lengthen by extending section 421 (see arrows 424 ). Each cylinder 414 , 415 is pinned or otherwise connected to chassis 213 .
[0127] An operator may control the arms 408 , 409 to lift the spool 300 (or spool 300 plus base 406 ) off the ground and place the spool 300 (or spool 300 plus base 406 ) onto the bed 402 of the crawler 212 in an upright position (see FIGS. 7-9, 12 and 1-3 ). The lifting subsystem 404 of the crawler 212 may also be used to load and offload the spools 300 (or spool 300 plus base 406 ) from the conveyance vehicles 204 .
[0128] Each cylinder 414 , 415 pushrod 422 , 423 is connected (pinned) to an arm 408 or 409 (see FIGS. 14-18 ). Pushrod 422 is pinned or pivotally attached at 416 to arm 408 . Pushrod 423 is pinned or pivotally connected at 417 to arm 409 . Each of the arms 408 , 409 provides a free end portion in the form of a fitting 425 or 426 . The arm 408 provides fitting 425 . The arm 409 provides fitting 426 . Each of the fittings 425 , 426 can be in the form of a projecting portion, eyelet, or other lifting device that can be used to form a connection with a lifting sling that also connects to the reel 300 . Fittings 425 , 426 can each support or shackle to connect with a sling. The reel 300 could provide a hub or drum 308 that could be configured to form a connection with an eyelet of a lifting sling. Such lifting slings are commercially available and known. Slings are typically in the form of an elongated cable having a loop at each end portion of the cable. To lift a spool, two slings would be employed. Each sling would be attached to an arm 408 , 409 at a fitting 425 or 426 . Each sling would connect to spool 300 at hub or drum 308 .
[0129] FIGS. 24-28 show a spool 300 supported upon its base 406 and prior to be loaded upon the deck or bed 402 of vehicle 212 . In order to lift the spool 300 and its base 406 upon chassis 213 of vehicle 212 , the fittings 425 , 426 of arms 408 , 409 would each be provided with a sling 427 . Typically, such a lifting sling 427 would have eyelet end portions, one eyelet end portion attached to a fitting 425 of arm 408 , the other sling having an eyelet that would be attached to the fitting 426 of the arm 409 . These two slings would then be connected to opposing sides of the hub or drum 308 of spool 300 . The spool 300 and its base 406 would then be lifted upwardly as illustrated by the arrows 427 .
[0130] FIGS. 29-34 schematically illustrate lifting subsystem 404 of vehicle 212 lifting spool 300 from a ground surface 352 . FIGS. 29 and 30 are respectively side and perspective views of the reel lifting system 404 about to pick up a reel 300 . Sling 427 is used to connect reel 300 to ends 425 and 426 of arms 408 , 408 . FIG. 31 is an enlarged perspective view of a connection using lifting slings 427 between the reel lifting system 300 and the reel 300 . FIGS. 32 and 33A are rear views of the reel lifting system 404 about to pick up a reel 300 from the ground 352 . FIG. 33B is an enlarged view of a connection (sling 427 ) between the reel lifting system 404 and reel 300 . During this movement rods 422 and 423 are respectively retracted into pistons 414 and 415 causing arms 408 and 409 to move in the direction of arrow 492 . FIG. 34 is a side view of reel lifting system 404 , having picked up reel 300 and now in mid path with motion schematically indicated by arrow 492 . FIG. 35 is a side view of reel lifting system 404 now placing the lifted reel 300 on deck 802 .
[0131] After being placed on deck 802 , drive axle subsystem 502 can be operably connected to reel 300 , to control rotation of reel 300 . FIG. 39 shows this type of connection with arrow 598 schematically indicating that telescoping section 520 can be extended in the direction of arrow 598 to operable couple reel 300 with drive axle subsystem 502 .
[0132] FIG. 36 is a perspective view of reel lifting system 404 about to pick up a reel 300 from a raised deck area 358 such as a trailer. In order to attach sling 427 to reel 300 at this upper height H, telescoping arms 420 and 421 can be selectively extended and/or retracted by an operator. Arrows 498 schematically indicate selective extension and/or retraction of arms 420 and 421 relative to arms 408 and 409 . As shown in FIG. 18 a hydraulic piston/cylinder type arrangement can be used to extend and/or retract arms 420 , 421 relative to arms 408 , 409 . FIG. 37 is a perspective view of the reel lifting system of the vehicle in mid path when loading a reel. During this movement rods 422 and 423 are respectively retracted into pistons 414 and 415 causing arms 408 and 409 to move in the direction of arrow 492 . Additionally, telescoping arms 420 and 421 can be selectively retracted (schematically indicated by arrow 493 ) into arms 408 and 409 causing spool 300 to be lowered towards deck 802 . FIG. 38 is a perspective view of the reel lifting system of the vehicle placing the reel on the deck of the vehicle. During this movement telescoping arms 420 and 421 can be selectively retracted by an operator to place base 350 of reel 300 on deck 802 of vehicle 212 .
[0000] Couplings for Lay Flat Hose Sections Any type of coupling 310 suitable for connecting two ends of the lay flat hose 304 may be used. For example, in one or more embodiments, the first end 306 of each laid hose segment 304 may be connected to the second end 312 of the previously laid lay flat hose segment 304 using an easy to connect, unisex coupling 310 that substantially eliminates water leakage and has a suitable pressure rating. In the foregoing described manner, the lay flat hose 304 may be connected in series, from end to end, until a pipeline 216 spanning at least the length from the water source 208 to the frac water destination 210 , or vice-versa, is constructed.
Components of Pipeline Incorporating Laid Out Hose
[0133] One or more pumps 218 may be integrated within the pipeline 216 to force the flow of water through the pipeline 216 . One or more filter pods 220 may also be integrated within the pipeline 216 to remove particulate matter originating from the water source 208 before the frac water reaches its destination 210 . More than one lay flat hose 304 pipelines 216 may be constructed as part of the rapid deployment and retrieval of a system for transferring frac water. As previously described, design parameters 222 may be determined based in part on insight gained from the computer program product 224 .
[0134] U.S. Provisional Application No. 61/479,641 and U.S. Pub. No. 2010/0059226 A1 are incorporated herein by reference in their entirety. Furthermore, where a definition or use of a term in a reference, which is incorporated by reference herein is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0135] One or more embodiments of the invention are directed to methods for the rapid deployment and retrieval of frac water transfer systems in accordance with embodiments of the invention.
[0136] Accordingly, compared to conventional methods, embodiments of the present invention may substantially reduce the number of person-hours and the number of one-way vehicular trips required to complete the pipeline, thereby reducing cost and the potential for harm to humans and the environment.
Locking and Unlocking System for Reel
[0137] FIG. 52 is a front perspective view of vehicle 212 from the non-driver side and showing the reel locking system 850 . FIG. 53 is a front perspective view of vehicle 212 with a reel 300 loaded on the vehicle bed 800 and the reel locking system 850 in an unlocked state. FIG. 54 is an enlarged perspective view of the reel locking system 850 shown in an unlocked state. FIG. 55 is a front perspective view of vehicle 212 with the reel locking system 850 in a locked state so that pivoting arm 860 has pivoted over base 350 of reel 300 . FIG. 56 is an enlarged perspective view of the reel locking system 850 shown in the locked state. To move from the locked to unlocked state, controller 870 can cause arm 860 to rotate in the direction of arrow 862 and away from base 350 .
[0138] Reel locking system 850 can include a pivoting arm 860 which pivots in the direction of arrow 862 over base 350 to lock reel 300 in position. Controller 870 can place reel locking system in locked and unlocked states.
[0139] The following is a list of reference numerals used in this application:
[0000]
REFERENCE NUMERAL LISTING:
REFERENCE NUMBER
DESCRIPTION
200
system
202
one or more spools or reels
204
one or more conveyance vehicles
206
equipment site
208
water source
210
frac water destination
212
off-road vehicles/crawler
213
tracked chassis/under carriage
214
various other types of equipment
216
current pipeline
218
one or more pumps
290
arrow
300
reel
301
axis
302
spokes
304
one or more segments of lay flat hose
306
first end
308
drum
310
coupling
312
second end
314
section of laid out hose
316
section of laid out hose with water
318
section of hose with water removed
320
bearing
330
connection with reel drive system
350
spool's base
352
ground
358
elevated surface
404
lifting subsystem
406
spool's base
408
arm
409
arm
410
one or more linkages
414
one or more hydraulic cylinder
415
hydraulic cylinder
416
pivotal connection
417
pivotal connection
418
pinned connection
419
pinned connection
420
extendable section
421
extendable section
422
pushrod
423
pushrod
424
arrow
425
fitting
426
fitting
427
shackle
490
arrow
492
arrow
493
arrow
494
arrow
496
arrow
498
arrow
502
drive axle subsystem
504
drive shaft
506
axial shaft
508
first gear
510
second gear
511
motor
512
chain
513
guard
520
telescoping connection
522
first end
524
second end
530
first section
540
second section
550
connection
552
locking connection
590
arrow
592
arrow
596
arrow
602
tensioning subsystem
603
roller
604
roller
605
roller
606
support structure
608
take up deck
609
handle
610
pivot
611
rod
612
coupling
620
support cup
622
plurality of bearings
612
hydraulic cylinder
690
arrow
692
arrow
694
arrow
696
arrow
698
arrow
704
one or more design parameters
706
computer program product output
708
step
710
step
712
step
714
step
716
step
718
lay flat hose pipeline
720
step
802
bed/deck
803
cab/cabin
850
reel locking system
860
pivoting arm
862
arrow
864
arrow
870
arrow
890
arrow
892
arrow
894
arrow
900
arrow
910
arrow
920
arrow
930
arrow
940
arrow
1000
first end
1010
second end
[0140] The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.
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A method of and apparatus for the rapid deployment of a fracturing water transferring system, along with the rapid picking up and storage of such system after use. In different embodiments the method in includes the use of a tensioning system to retrieve one or more segments of lay flat hose.
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FIELD OF INVENTION
The present invention relates to magnetostrictive transducers and, more specifically, to a two-way communication device or intercom comprising a magnetostrictive transducer. The magnetostrictive transducer operates in a transmission mode to convert electrical audio signals into sound waves and in a reception mode to convert audio signals into electrical audio signals.
BACKGROUND
It is known to provide two-way communication devices or intercoms for a wide variety of uses and applications, but generally they allow communication between two parties across a secure barrier. For example, these devices find application at entry points to homes and flats, in banks where they facilitate communication between bank tellers and customers and in public telephones. By virtue of their very application, two-way communication devices are usually located in public places. Consequently, they are required to be vandal proof and weatherproof.
Conventional two-way communication devices typically comprise loudspeakers, microphones and switches housed within a robust outer casing having apertures in the front face to allow sound waves to enter and leave the device and to locate the switches. Often, attacks by vandals on these devices involve objects being pushed through these apertures to damage or destroy the loudspeaker and microphone diaphragms or to jam the switches. Other attacks can take the form of various liquids such as chewing gum, vomit or super glue introduced through the apertures causing a variety of malfunctions.
SUMMARY
It is an object of the present invention to provide a two-way communication device which is not vulnerable to physical attack.
It is yet another object of the present invention to provide a two-way communication device which does not require apertures to be formed in the outer casing thereof for the transmission of sound waves to and from the audio transducers located within the outer casing.
It is still another object of the present invention to provide a two-way communication device comprising an audio transducer which combines the functions of loudspeaker and microphone.
These objects are achieved by providing a two-way communication device comprising an audio transducer connected to a panel or face of the outer casing which operates as a diaphragm thereby converting sound waves into electrical signals at the output of the audio transducer and vice versa. Conveniently, the front panel of the outer casing forms the diaphragm.
According to the present invention there is provided a two-way communication device comprising a magnetoelastic rod located between an inertial back mass and a front panel of low mass, a coil located in the vicinity of the said rod, the rod and coil together defining an audio-electric transducer, and electronic processing means whereby an audio-electric signal input to the device is applied to the coil to produce a sound wave from the said low mass panel and a sound wave impinging on the said low mass panel produces an audio-electric signal which is output from the device.
Preferably, the magnetoelastic rod is comprised of a magnetostrictive material, such as Terfenol with a typical constitution of Tb 0.3 Dy 0.7 Fe 1.95 .
It is known within the prior art to provide loudspeakers which are based on the magnetostrictive effect. For the purposes of explanation and clarification the magnetostrictive effect is the property of certain materials to undergo a geometrical modification, e.g. contraction, expansion, bending, twisting, etc., when subjected to the influence of a magnetic field. Metal alloys and more specifically ferromagnetic compounds are magnetostrictive materials.
French Patent No. 7702333 discloses a magnetostrictive device which operates as a loudspeaker to convert electrical signals into sound waves. Essentially the device comprises a bar of magnetostrictive material arranged within a coil. When a varying voltage is applied to the coil it produces a magnetic field which causes the magnetostrictive bar to expand or contract. At each of the ends of the magnetostrictive bar, this produces an elastic wave. By connecting one or each end of the magnetostrictive bar to a diaphragm this elastic wave can be converted into sound waves corresponding to the electrical signal applied to the coil.
Preferably, the said low mass panel is defined by the front panel of an outer casing. Alternatively, the front panel may form a solid surface to which the audio transducer is mounted. Conveniently, the said low mass panel is comprised of stainless steel or some other strong, yet flexible material. The present invention ensures that damage to the internal workings of the device is prevented by presenting an outer casing which has no accessible apertures in it and which presents the appearance of a plain, unbroken sheet of solid stainless steel.
In one embodiment of the present invention a single coil is provided in the vicinity of magnetoelastic rod which simultaneously carries the electrical signals corresponding to audio-out and audio-in. These two signals are separated within the said processing means. However, as an alternative to this a first drive coil may be provided in the vicinity of the magnetoelastic rod which carries the electrical signal corresponding to the audio-out and a second high-turn sense coil may be provided, again within the vicinity of the magnetoelastic rod, which carries the electrical signal corresponding to the audio-in. As yet a further alternative, the sense coil may be replaced with flux sensor that relies on changes in the magneto resistance of the circuit or the Hall effect to provide an electrical output corresponding to the audio-in.
Preferably, the magnetoelastic rod is biased into the linear region of its response characteristic by positioning a permanent magnet in proximity thereto. As an alternative to this a DC voltage may be applied to the drive coil to bias the magnetoelastic rod into this region.
Preferably, the electronic processing means comprises means for detecting electrical impulses in the coil having a rate of change in excess of a predetermined value, corresponding to the low mass panel being touched. This allows the device to provide a switch facility which may be used, for example, to operate an audible or visual device to attract attention.
In addition to operating the magnetoelastic rod to cause the low mass panel to vibrate and generate a sound wave, the magnetic field generated by the coil allows the electrical audio-out signal to be picked up by hearing aids. This coupling facility is, of course, useful to those with impaired hearing.
Conveniently, the electronic processing means incorporating audio drive, audio sense electronics, and touch detecting circuits is incorporated into the inertial core of the magnetoelastic transducer.
The two-way communication device of the present invention integrates the functions of loudspeaker, microphone and, optionally, switch and hearing aid coupler in a single transducer which is enclosed in a casing that can be small, rugged, vandal resistant and hermetically sealed.
BRIEF DESCRIPTION OF DRAWINGS
An embodiment of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a cross-sectional view through a two-way communication device embodying the present invention;
FIG. 2 is a circuit diagram of an audio signal processor circuit suitable for use in a two-way communication device according to the present invention comprising a single coil; and,
FIG. 3 is a circuit diagram of a voltage threshold detector for use in a two-way communication device according to the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1 of the drawings there is shown in cross-section a two-way communication device or intercom embodying the present invention. The device comprises an outer casing 9 , housing an audio transducer comprising a rod 4 of magnetostrictive material, a drive coil 13 and a sense coil 5 . Both the drive coil 13 and the sense coil 5 are coiled around the rod 4 . The rod 4 is held between an inertial back mass 8 and a front panel 1 of the device and, more specifically, a flexible diaphragm 6 formed in and integral with the front panel 1 . The diaphragm 6 is supported within the front panel 1 on flexural supports 2 . As will be explained in greater detail herein below the audio transducer operates as both a loudspeaker and as a microphone with sound waves being generated by the diaphragm 6 in response to audio-out signals and sound waves being picked up by the diaphragm 6 to generate an audio-in signal.
A tubular permanent magnet 3 surrounds the rod 4 and the sense coil 5 . This permanent magnet 3 serves to bias the magnetostrictive material comprising the rod 4 into the linear region of its response characteristic. As an alternative to providing a permanent magnet, however, this can be achieved by connecting a DC biasing voltage to the drive coil 13 . The audio signal processing circuits associated with the device are provided on a circuit board 11 mounted on the back of the inertial mass 8 .
The recess defined by the outer case 9 is dimensioned so as to ensure that the transducer is positioned at a precise distance from the diaphragm 6 . The outer case 9 provides a means to hold and align the inertial mass 8 via ‘O’ rings ( 7 ). Finally, a pre-stress spring 12 is located between the outer case 9 and the inertial mass 8 which serves to maximise the strain in the magnetostrictive rod 4 .
In use, an audio-in signal applied to the drive coil 13 produces a fluctuating magnetic field around the rod 4 which causes it to expand and contract. This in turn causes the diaphragm 6 to vibrate and produce a sound wave corresponding to the audio-in signal. The same diaphragm 6 is also responsive to sound waves impinging thereon to vibrate and to cause the rod 4 to change in length in response thereto. As the length of the rod 4 fluctuates this generates a fluctuating magnetic field which in turn creates a fluctuating electrical signal in the drive coil 13 . Using appropriate circuitry such as that shown in and described with reference to FIG. 2 hereinbelow, the electrical audio-in and audio-out signals in the drive coil 13 can be processed. However, as an alternative to using the one coil 13 to both drive the diaphragm and to sense vibration thereof, the device as shown in FIG. 1 comprises a dedicated high-turn sense coil 5 . Yet another way of detecting changes in the magnetic flux of the rod 4 caused by sound waves impinging on the diaphragm 6 is to use a flux sensor 10 . In practice, only one of these three means is likely to be used at any one time.
The rod 4 of magnetostrictive material may be comprised of Terfenol with a typical composition of Tb 0.3 Dy 0.7 Fe 1.95 for example, or similar material with similar properties. A material of this kind is chosen for its efficient conversion of magnetic to mechanical energy and vice versa. Applying a mechanical pre-stress using the springs 12 and magnetic bias field using the permanent magnet 3 optimises the material performance. The springs 12 also provide shock protection to the magnetostrictive material. As shown in FIG. 1 the inertial mass 8 is suspended in the outer case 9 , using high compliance ‘O’ rings. However in another embodiment the inertial mass can be replaced by the mass of the outer casing 9 itself.
The assembled transducer is integrated into the solid front panel of the relevant product to produce a solid and robust unit that will be resistant to physical abuse and present a solid unbroken external surface. An alternative embodiment will have the transducer manufactured as a separate entity, which can then be mounted into a solid surface that will act both as a receiver and transmitter of sound. Depending on the application, the transducer front panel can be bonded or screwed to a mounting surface. Irrespective of the mounting method, no holes are required in the front panel and the unit is therefore immune to typical vandal attacks such as poking and gluing.
As shown in FIG. 1 the rod 4 is directly coupled to the steel front panel 1 so that the acoustic matching is good. In other embodiments acoustic matching is provided by, for example, matching layers or acoustic impedance transformers familiar to those versed in the art.
Integral to the successful embodiment of audio-in and audio-out in a single device is an electronic subsystem comprising coil drivers, audio amplifiers and detection circuits. Because both the audio drive and receive signals are coupled by the magnetostrictive material, means have to be provided for separating these signals to prevent acoustic feedback.
Referring to FIG. 2 of the drawings there is shown an electronic hybrid circuit which is able to separate the transmit (loudspeaker) and receive (microphone) signals, thereby preventing acoustic feedback. Operational amplifier A 1 simply provides a gain of ×2 to the ‘Audio-In’ signal obtained from a source external to the device itself. This compensates for the reduction of the output of A 1 to ½ caused by the potential divider formed by the impedance matching Zo and the ‘Drive Coil’ Zo. Thus the drive signal level at the ‘Drive Coil’ is equal to ‘Audio-In’ in amplitude, but has been inverted by A 1 . A non-inverted copy of ‘Audio-In’ is mixed with the inverted signal at the input to operational amplifier A 2 . The operation of A 2 is to cancel both signals so eliminating ‘Audio-In’ from the output of A 2 . The final function of A 2 is to amplify the output of the ‘Drive Coil’ that is generated in microphone mode by a factor of AR/R=A.
Referring now to FIG. 3 there is shown a voltage threshold detector circuit which consists of a differentiator and a Schmitt trigger. The input signal applied to this circuit is the ‘Audio-Out’ signal obtained from the circuit of FIG. 2 . With normal speech signals as the input to the drive coil the ‘Audio-Out’ signal will have a limited rate of change of voltage. However, when the diaphragm is tapped sharply, the rate of change of the resulting output signal from the drive coil will be much greater and the amplitude will generally be greater. This signal will be passed preferentially through capacitor C and presented to the input of the operational amplifier A 3 . Since this transient signal will be negative going, the −ve input to A 3 is biased at a suitable −ve level that will not respond to small, low rate-of-change signals. This threshold level is set by the ratio of R/(R+nR). The resistor kR provides a degree of hysteresis to provide a ‘clean’ signal at ‘Switch Out’.
It will be apparent from the description given above that the present invention provides a highly integrated multi-functional audio transducer that provides means for transmitting and receiving sound, and optional acting as a control switch input. A further advantage of the invention is that the magnetic field generated in the drive coil can be coupled to hearing aids. All of these functions are provided in a single audio transducer which is operatively connected to a diaphragm formed as an integral part of a stainless steel sheet front panel that has no external apertures or electrical connections that would make the unit vulnerable to attack.
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A two-way communication device includes a magnetoelastic rod located between an inertial back mass and a front panel of low mass. A coil is located in the vicinity of the rod, and the rod and coil together define an audio-electric transducer. An electronic processing circuit ensures that an audio-electric signal input to the device is applied to the coil to produce a sound wave from the low mass front panel and that when a sound wave impinges on the low mass front panel an audio-electric signal is produced and output from the device.
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FIELD OF THE INVENTION
The invention relates to warewashing processes and chemicals used in washing plastic cookware, dishware and flatware. More particularly, the invention relates to primarily organic materials that can be added to water to promote a sheeting action in an aqueous rinse used after an alkaline detergent cycle. Such aqueous rinse aids promote effective sheeting to result in removal of aqueous rinse materials and solids contained therein from plastic cookware, dishware and flatware in acceptable drying time without cracking the plasticware.
BACKGROUND OF THE INVENTION
Mechanical warewashing machines have been common in the institutional and household environments for many years. Such automatic warewashing machines clean dishes using two or more cycles which can include initially a wash cycle followed by a rinse cycle. Such dishwashers can also utilize soak cycle, prewash cycle, scrape cycle, second wash cycle, a rinse cycle, a sanitizing cycle and a drying cycle, if required. Such cycles can be repeated if needed and additional cycles can be used. After passing through a wash, rinse and dry cycle, dishware, cups, glasses, etc., can exhibit spotting that arises from the uneven draining of the water from the surface of the ware after the rinse step. Spotting is aesthetically unacceptable in most consumer and institutional environments.
In order to substantially prevent the formation of spotting rinse agents have commonly been added to water to form an aqueous rinse which is sprayed on the dishware after cleaning is complete. The precise mechanism through which rinse agents work is not established. One theory holds that the surfactant in the rinse aid is absorbed on the surface at temperatures at or above its cloud point, and thereby reduces the solid-liquid interfacial energy and contact angle. This leads to the formation of a continuous sheet which drains evenly from the surface and minimizes the formation of spots. Generally, high foaming surfactants have cloud points above the temperature of the rinse water, and, according to this theory, would not promote sheet formation, thereby resulting in spots. Moreover, high foaming materials are known to interfere with the operation of the warewashing machine. Common rinse aid formulas are used in an amount of less than about 1,000 parts preferably less than 500 parts, commonly 50 to 200 parts per million of active materials in the aqueous rinse. Rinse agents available in the consumer and institutional markets comprise liquid or solid forms which are typically added to, dispersed or dissolved in water to form an aqueous rinse. Such dissolution can occur from a rinse agent installed onto the dish rack. The rinse agent can be diluted and dispensed from a dispenser mounted on or in the machine or from a separate dispenser that is mounted separately but cooperatively with the dish machine.
Commonly available commercial rinse agents typically comprise a low foaming surface active agent made from homopolymers or copolymers of an alkylene oxide such as ethylene oxide or propylene oxide or mixtures thereof. Typically, the surfactants are formed by reacting an alcohol, a glycol, a carboxylic acid, an amine or a substituted phenol with various proportions and combinations of ethylene oxide and propylene oxide to form both random and block copolymer substituents.
The commonly available rinse agents have primarily focused on reducing spotting and filming on surfaces such as glass, ceramics, china and metal. However, plastic dishware is more commonly used now, especially in the institutional market. A special problem for rinse aid surfactants used for plasticware is the attack and crazing of the ware. Block copolymer surfactants do not seem to attack plastics as strongly as fatty alcohol or alkyl phenol-based nonionic surfactants. Linear alkoxylates show they do not attack plexiglass, polystyrene, or Tupperware®, common utensil plastics. Nevertheless, current surfactants have not provided the desired sheeting in an acceptable drying time following the rinse cycle.
U.S. Pat. No. 5,298,289 describes the treatment and after-treatment of surfaces, especially metals, with derivatives of polyphenol compounds. These compositions are also said to be useful in treating plastic and painted surfaces to improve rinsability without water breaks. The surfactants employed are a combination of previously known anionic and nonionic surfactants.
Liquid dishwashing detergent compositions are described in U.S. Pat. No. 4,492,646 containing highly ethoxylated nonionic surfactants to reduce spotting and filming on surfaces such as glass, ceramics and metal.
European Patent Publication 0,432,836 describes the use of alkyl polyglycoside surfactants in rinse aid compositions on polycarbonate.
Fluorinated surfactants are described in U.S. Pat. No. 4,089,804 where a non-ethoxylated fluoroaliphatic sulfonamide alcohol is added to typical fluorinated hydrocarbon surfactants as a synergist. The compositions are described as useful in a wide variety of industries, e.g., household cosmetic and personal products. Rinse aid for dishwashing is mentioned.
Organosilanes are described in rinse aid compositions where the organosilane contains either a nitrogen, phosphorous or sulfur cationic group in combination with an anion, e.g. a monofunctional organic acid. U.S. Pat. No. 4,005,024 describes such compounds in a rinse aid composition to attract specific soil particles.
Aminosilanes have been described with a low foaming ethoxylated nonionic surfactant in rinse aid compositions in automatic dishwashing machines.
None of the fluorinated surfactants or silanes described in rinse aid compositions have focused on their use in plasticware.
Surprisingly, we have found that by adding a combination of a fluorinated hydrocarbon surfactant, especially an ethoxylated fluorinated aliphatic sulfonamide alcohol, with a silane surfactant, e.g. a polyalkylene oxide-modified polydimethylsiloxane, to a conventional rinse aid composition containing hydrocarbon surfactants, the resulting rinse agent provides excellent sheeting properties on plasticware without attacking or crazing the plastic and, more importantly, providing dried, non-spotted plasticware in acceptable time following the rinse cycle.
SUMMARY OF THE INVENTION
Accordingly, the present invention is a rinse aid composition for plasticware, formulated as a dilutable liquid, gel or solid concentrate and., when diluted, forming an aqueous rinse, and including in addition to conventional rinse aid surfactants, e.g. hydrocarbon surfactants, a combination of about 0.1 to 10 wt % of a fluorinated hydrocarbon nonionic surfactant and about 0.1 to 10 wt % of a polyalkylene oxide-modified polydimethylsiloxane.
A second aspect of the present invention is a method of cleaning plasticware by: (a) first contacting the ware with an alkaline aqueous cleaning agent in a warewashing machine at 100°-180° F. to produce cleaned plasticware, and (b) contacting the cleaned plasticware with an aqueous rinse containing a major proportion of an aqueous diluent having about 2 to 100 parts per million of hydrocarbon surfactants, and a combination of about 0.01 to 10 parts per million of a fluorinated hydrocarbon surfactant, e.g. an ethoxylated fluoroaliphatic sulfonamide alcohol, and about 0.01 to 10 parts per million of a polyalkylene oxide-modified polydimethylsiloxane.
DETAILED DESCRIPTION OF THE INVENTION
For the purpose of this invention, the term "rinse agent" includes concentrate materials that are diluted with an aqueous stream to produce an aqueous rinse. Accordingly, an aqueous rinse agent is an aqueous material that is contacted with ware in a rinse cycle. A sheeting agent is the polymeric material used to promote the even draining of the aqueous rinse. Sheeting is defined as forming a continuous, evenly draining film, leaving virtually no spots or film upon the evaporation of water. For the purpose of this invention, the term "dish" or the term "ware" is used in the broadest sense of the term to refer to various types of articles used in the preparation, serving, consumption, and disposal of food stuffs including pots, pans, trays, pitchers, bowls, plates, saucers, cups, glasses, forks, knives, spoons, spatulas, and other glass, metal, ceramic, plastic composite articles commonly available in the institutional or household kitchen or dining room.
Since the present invention focuses on plastic articles, the term "plasticware" includes the above articles made from, e.g., polycarbonate, melamine, polypropylene, polyester resin, polysulfone, and the like.
The fluorochemical surfactant employed as an additive in the present invention in combination with a silane, defined below, is a nonionic fluorohydrocarbon, such as, for example, fluorinated alkyl polyoxyethylene ethanols, fluorinated alkyl alkoxylate and fluorinated alkyl esters. These Fluorad™ surfactants are available from 3M. As a fluorinated alkyl polyoxyethylene ethanol, included as a preferred surfactant is a polyoxyethylene adduct of a fluoroaliphatic sulfonamide alcohol which has excellent wetting, spreading and levelling properties. These surfactants may be described as having the formula:
R.sub.f SO.sub.2 N(C.sub.2 H.sub.5)(CH.sub.2 CH.sub.2 O).sub.x H
wherein R f is C n F 2n+1 in which n is 6-10 and x may vary from 10 to 20. Particularly valuable is the surfactant where n is 8 and x is 14. This particular surfactant identified as FC-170C is also available from 3M.
The siloxane surfactant employed as an additive in the present invention in combination with the above fluorochemical surfactant is a polyalkylene oxide-modified polydimethylsiloxane, preferably a linear polydimethylsiloxane to which polyethers have been grafted through a hydrosilation reaction. This process results in an alkyl-pendant (AP type) copolymer, in which the polyalkylene oxide groups are attached along the siloxane backbone through a series of hydrolytically stable Si--C bonds. These products have the general formula: ##STR1## wherein EO is ethyleneoxy, PO is 1,2-propyleneoxy, Z is hydrogen or alkyl of 1-6 carbon atoms, and the weight ratio in % of EO:PO may vary from 100:0 to 0-100. A broad range of surfactants have been developed varying x and y above and coefficients n and m. Preferably, n is 0 or 1 and m is at least 1. More preferred are the siloxanes where n is 0 or 1, m is 1, Z is hydrogen or methyl and the weight ratio of EO:PO is 100:0 to 20:80. Particularly valuable are the siloxanes where n is 0, Z is methyl and the weight ratio of EO:PO is 100:0 to 20:80. The siloxane surfactants herein described are known as SILWET® surfactants available from Union Carbide or ABIL® polyethersiloxanes available from Goldschmidt Chemical Corp. The particular siloxanes used in the present invention are described as having, e.g., low surface tension, high wetting ability and excellent lubricity. For example, these surfactants are said to be among the few capable of wetting polytetrafluoroethylene surfaces.
Although the fluorochemical surfactants and siloxane surfactants were known to have good wetting properties, the use of each surfactant alone with conventional rinse aid surfactants on plasticware did not perform as well as the combination and only marginally better than a conventional rinse agent without additives.
Since the use of the above additives in combination, i.e. the fluorocarbon and the siloxane, are applicable to all conventional rinse aid formulations, the following description of ingredients and rinse aid formulations is illustrative only and not limiting of the present invention.
An example of hydrocarbon surfactants in conventional rinse aid formulations are nonionic surfactants, typically a polyether compound prepared from ethylene oxide, propylene oxide, in a homopolymer or a block or heteric copolymer. Such polyether compounds are known as polyalkylene oxide polymers, polyoxyalkylene polymers, or polyalkylene glycol polymers. Such sheeting or rinse agents have a molecular weight in the range of about 500 to about 15,000. Certain types of polyoxypropylene-polyoxyethylene glycol polymer rinse aids have been found to be particularly useful. Those surfactants comprising at least one block of a polyoxypropylene and having at least one other block of polyoxyethylene attached to the polyoxypropylene block. Additional blocks of polyoxyethylene or polyoxypropylene can be present in a molecule. These materials having an average molecular weight in the range of about 500 to about 15,000 are commonly available as PLURONIC® manufactured by the BASF Corporation and available under a variety of other trademarks of their chemical suppliers. In addition, rinse aid compositions called PLURONIC® R (reverse pluronic structure) are also useful in the rinse aids of the invention. Additionally, rinse aids made by reacting ethylene oxide or propylene oxide with an alcohol anion and an alkyl phenol anion, a fatty acid anion or other such anionic material can be useful. One particularly useful rinse aid composition can comprise a capped polyalkoxylated C 6-24 linear alcohol. The rinse aids can be made with polyoxyethylene or polyoxypropylene units and can be capped with common agents forming an ether end group. One particularly useful species of this rinse aid is a benzyl ether of a polyethoxylated C 12-14 linear alcohol; see U.S. Pat. No. 3,444,247. Alcohol ethoxylates having EO and PO blocks can be particularly useful since the stereochemistry of these compounds can permit occlusion by urea, a feature useful in preparing solid rinse aids.
Particularly useful polyoxypropylene polyoxyethylene block polymers are those comprising a center block of polyoxypropylene units and blocks of polyoxyethylene units to each side of the center block. These copolymers have the formula shown below:
(EO).sub.n -(PO).sub.m -(EO).sub.n
wherein m is an integer of 21 to 54; n is an integer of 7 to 128. Additional useful block copolymers are block polymers having a center block of polyoxyethylene units and blocks of polyoxypropylene units to each side of the center block. The copolymers have the formula as shown below:
(PO).sub.n -(SO).sub.m -(PO).sub.n
wherein m is an integer of 14 to 164 and n is an integer of 9 to 22.
In the preparation of conventional rinse aid compositions, a hydrotropic agent is often employed in the formulation. Such an agent may also be used in the present invention.
Hydrotropy is a property that relates to the ability of materials to improve the solubility or miscibility of a substance in liquid phases in which the substance tends to be insoluble. Substances that provide hydrotropy are called hydrotropes and are used in relatively lower concentrations than the materials to be solubilized.
A hydrotrope modifies the solvent to increase the solubility of an insoluble substance or creates micellar or mixed micellar structures resulting in a stable suspension of the insoluble substance in the solvent. The hydrotropic mechanism is not thoroughly understood. Apparently either hydrogen bonding between primary solvent, in this case water, and the insoluble substance are improved by the hydrotrope or the hydrotrope creates a micellar structure around the insoluble composition to maintain the material in a suspension/solution. In this invention, the hydrotropes are most useful in maintaining a uniform solution of the cast rinse composition both during manufacture and when dispersed at the use location. The combination of the polyalkylene oxide materials and the casting aids tends to be partially incompatible with aqueous solution and can undergo a phase change or phase separation during storage of the solution. The hydrotrope solubilizer maintains the rinse composition in a single phase solution having the nonionic rinsing agent uniformly distributed throughout the composition.
Preferred hydrotrope solubilizers are used at about 0.1 to 20 wt % and include small molecule anionic surfactants. The most preferred hydrotrope solubilizers are used at about 1 to 10 wt % and include aromatic sulfonic acid or sulfonated hydrotropes such as C 1-5 substituted benzene sulfonic acid or naphthalene sulfonic acid. Examples of such a hydrotrope are xylene sulfonic acid or naphthalene sulfonic acid or salts thereof. Such materials do not provide any pronounced surfactant or sheeting activity but significantly improve the solubility of the organic materials of the rinse aid in the aqueous rinse compositions.
Thus, a preferred embodiment of a rinse aid composition for plasticware, which is suitable for dilution to form an aqueous rinse includes: (a) about 2 to 90 wt % of one or more nonionic surfactants; (b) about 1 to 20 wt % of a hydrotrope; (c) about 0.1 to 10 wt % of an ethoxylated fluoroaliphatic sulfonamide alcohol; and (d) about 0.1 to 10 wt % of a polyalkylenoxide-modified polydimethylsiloxane.
Another embodiment of the rinse aid composition of the present invention is the combination of the above-described fluorocarbon surfactant and siloxane surfactant with a rinse aid composition containing a nonionic block copolymer and a defoamer composition. The nonionic ethylene oxide propylene oxide block copolymer in this case would not have been expected to provide effective sheeting action and low foam in an aqueous rinse due to its high cloud point and poor wetting properties. However, rinse agents diluted into an aqueous rinse providing effective sheeting and low foaming properties have been prepared from high cloud point, high foaming surfactants with an appropriate defoamer as described in copending U.S. application Ser. No. 08/049,973 of Apr. 20, 1993.
Illustrative but non-limiting examples of various suitable high cloud point nonionic surface active agents for these rinse agents include polyoxyethylenepolyoxypropylene block copolymers having the formula:
(EO).sub.x (PO).sub.y (EO).sub.z
wherein x, y and z reflect the average molecular proportion of each alkylene oxide monomer in the overall block copolymer composition. x typically ranges from about 30 to 130, y typically ranges from about 30 to 70, z typically ranges from about 30 to 130, and x plus y is typically greater than about 60. The total polyoxyethylene component of the block copolymer constitutes typically at least about 40 mol-% of the block copolymer and commonly 75 mol-% or more of the block copolymer. The material preferably has a molecular weight greater than about 5,000 and more preferably greater than about 10,000.
Defoaming agents (defoamers) include a variety of different materials adapted for defoaming a variety of compositions. Defoamers can comprise an anionic or nonionic material such as polyethylene glycol, polypropylene glycol, fatty acids and fatty acid derivatives, fatty acid sulfates, phosphate esters, sulfonated materials, silicone based compositions, and others.
Preferred defoamers are food additive defoamers including silicones and other types of active anti-foam agents.
Silicone foam suppressors include polydialkylsiloxane preferably polydimethylsiloxane. Such silicone based foam suppressors can be combined with silica. Such silica materials can include silica, fumed silica, derivatized silica, silanated silica, etc. Commonly available anti-foaming agents combine a polydimethylsiloxane and silica gel. Another food additive defoaming agent comprises a fatty acid defoamer. Such defoamer compositions can comprise simple alkali metal or alkaline earth metal salts of a fatty acid or fatty acid derivatives. Examples of such derivatives include mono, di- and tri-fatty acid esters of polyhydroxy compounds such as ethylene glycol, glycerine, propylene glycol, hexylene glycol, etc. Preferably such defoaming agents comprise a fatty acid monoester of glycerol. Fatty acids useful in such defoaming compositions can include any C 8-24 saturated or unsaturated, branched or unbranched mono or polymeric fatty acid and salts thereof, including for example myristic acid, palmitic acid, stearic acid, behenic acid, lignoceric acid, palmitoleic acid, oleic acid, linoleic acid, arachidonic acid, and others commonly available. Other food additive anti-foam agents available include water insoluble waxes, preferably microcrystalline wax, petroleum wax, synthetic petroleum wax, rice base wax, beeswax having a melting point in the range from about 35° to 125° C. with a low saponification value, white oils, etc. Such materials are used in the rinse agents at a sufficient concentration to prevent the accumulation of any measurable stable foam within the dish machine during a rinse cycle. The defoaming composition may be present in the composition of the present invention from about 0.1-30 wt %, preferably 0.2-25 wt %.
Thus, a preferred rinse aid composition for plasticware, suitable for dilution to form an aqueous rinse also includes: (a) about 5 to 40 wt % of a nonionic block copolymer composition of ethylene oxide and propylene oxide, having a molecular weight of ≧5000 and a cloud point, measured with a 1 wt % aqueous solution, greater than 50° C.; (b) about 0.2 to 25 wt % of a food additive defoamer composition; (c) about 0.1 to 10 wt % of an ethoxylated fluoroaliphatic sulfonamide alcohol; and (d) about 0.1 to 10 wt % of a polyalkylene oxide-modified polydimethylsiloxane.
Still another embodiment of the present invention is a rinse aid composition containing the combination of the above-described fluorocarbon surfactant and siloxane surfactant with a rinse aid composition containing solely food additive ingredients. The compositions include a class of nonionic surfactants, namely, the polyalkylene oxide derivatives of sorbitan fatty acid esters, which exhibit surprising levels of sheeting action, with a careful selection of defoamer compositions. These are described in copending U.S. Application Ser. No. 08/050,531 of Apr. 20, 1993, now abandoned. The effective defoamer compositions are selected from the group consisting of a silicone defoamer, an alkali metal (e.g. sodium, potassium, etc.) or alkaline earth fatty acid salt defoamer or a glycerol fatty acid monoester defoamer described above. Preferably, silicone based materials are used to defoam the sorbitan material.
Sorbitol and sorbitan can be derivatized with an alkylene oxide such as ethylene oxide or propylene oxide or derivatized with fatty acids or with both using conventional technology to produce nonionic surfactant sheeting agent materials. These sheeting agents are typically characterized by the presence of from 1 to 3 moles of a fatty acid, in ester form, per mole of surfactant and greater than 15 moles of alkylene oxide, preferably 15 to 40 moles of alkylene oxide and most preferably 15 to 25 moles of ethylene oxide per mole of surfactant. The composition of the surfactant is a mixture of a large number of compounds characterized by the molar proportion of alkylene oxide and the molar proportion of fatty acid residues on the sorbitol or sorbitan molecules. The compositions are typically characterized by average concentrations of the alkylene oxide (typically ethylene oxide) and the fatty acid on the overall compositions. Examples of preferred nonionic surfactants are Polysorbate 20®, also known as Tween 20® (ICI), typically considered to be a mixture of laureate esters of sorbitol and sorbitan consisting predominantly of the mono fatty acid ester condensed with approximately 20 moles of ethylene oxide. Polysorbate 60® is a mixture of stearate esters of sorbitol and sorbitan consisting predominantly of the mono fatty acid ester condensed with approximately 20 moles of ethylene oxide. Selected polysorbate nonionic surfactant materials are approved for direct use in food intended for human consumption under specified conditions and levels of use.
Alkoxylated sorbitan or sorbitol aliphatic esters suitable for use in the rinse aid composition include any sorbitan or sorbitol aliphatic ester derivatized with an alkylene oxide capable of providing effective sheeting action or rinsing performance in cooperation with the other components of the rinse agent composition. The preferred compositions are the ethylene oxide condensates with sorbitan or sorbitol fatty acid esters. In addition to providing superior sheeting and rinsing performance, these materials are approved food additives, in the form of a liquid or waxy solid, that can be easily formulated into concentrated liquid or solid rinse agents. Alkoxylated sorbitan or sorbitol fatty acid esters suitable for use in the rinse agent include mono, di- and tri-esters and mixtures thereof. Sorbitan fatty acid esters may be derivatized by esterification of sorbitol or sorbitan with such fatty acids as lauric, myristic, palmitic, stearic, oleic, linoleic, and other well known similar saturated, unsaturated (cis or trans), branched and unbranched fatty acid. Preferred food additive or GRAS fatty acids are the sorbitan esters approved as direct food additives (e.g. sorbitan monostearate, POE 20 Sorbitan monolaurate, POE 20 Sorbitan monostearate, POE 20 Sorbitan tristearate, POE 20 Sorbitan monooleate and mixtures thereof. Based on their cost availability and ability to provide excellent sheeting action and rinsing performance, the preferred useful ethoxylated sorbitan or sorbitol fatty acid ester include monoesters derivatized with ethylene oxide.
Thus, a preferred rinse aid composition for plasticware, suitable for dilution to form an aqueous rinse, further includes: (a) about 5 to 50 wt % of a sorbitan fatty acid ester containing greater than about 15 moles of alkylene oxide per mole of sorbitan; (b) about 0.2 to 25 wt % of a defoamer composition selected from the group consisting of an alkali metal or alkaline earth metal salt of a fatty acid, a silicone, a fatty acid ester of glycerol, and mixtures thereof; (c) about 0.1 to 10 wt % of an ethoxylated fluoroaliphatic sulfonamide alcohol; and (d) about 0.1 to 10 wt % of a polyalkylene oxide-modified polydimethylsiloxane.
The rinse agents of the invention can, if desired, contain a polyvalent metal complexing or chelating agent that aids in reducing the harmful effects of hardness components in service water. Typically calcium, magnesium, iron, manganese, etc., ions present in service water can interfere with the action of either washing compositions or rinsing compositions. A chelating agent can effectively complex and remove such ions from inappropriate interaction with active ingredients increasing rinse agent performance. Both organic and inorganic chelating agents are common. Inorganic chelating agents include such compounds as sodium tripolyphosphate and higher linear and cyclic polyphosphate species. Organic chelating agents include both polymeric and small molecule chelating agents. Polymeric chelating agents commonly comprise polyanionic compositions such as polyacrylic acid compounds. Small molecule organic chelating agents include salts of ethylenediaminetetracetic acid and hydroxyethylenediaminetetracetic acid, nitrilotriacetic acid, ethylenediaminetetrapropionates, triethylenetetraminehexacetates, and the respective alkali metal ammonium and substituted ammonium salts thereof. Amino phosphates are also suitable for use as chelating agents in the composition of the invention and include ethylenediamine(tetramethylene phosphates), nitrilotrismethylenephosphonates, diethylenetriamine (pentamethylenephosphonates). These amino phosphonates commonly contain alkyl or alkyl groups with less than 8 carbon atoms. Preferred chelating agents include approved food additive chelating agents such as disodium salt of ethylenediaminetetracetic acid.
The liquid rinse agent compositions of the invention have a liquid base component which can function as a carrier with various aqueous diluents to form the aqueous rinse. Liquid bases are preferably water or a solvent compatible with water to obtain compatible mixtures thereof. Exemplary nonlimiting solvents in addition to water include low molecular weight C 1-6 primary and secondary mono, di-, and trihydrate alcohol such as ethanol, isopropanol, and polyols containing from two to six carbon atoms and from two to six hydroxyl groups such as propylene glycol, glycerine, 1,3-propane diol, propylene glycol, etc.
The compositions of the invention can be formulated using conventional formulating equipment and techniques. The compositions of the invention typically can comprise proportions as set forth in Table I.
In the manufacture of the liquid rinse agent of the invention, typically the materials are manufactured in commonly available mixing equipment by charging to a mixing chamber the liquid diluent or a substantial proportion of a liquid diluent. Into a liquid diluent is added preservatives or other stabilizers. Care must be taken in agitating the rinse agent as the formulation is completed to avoid degradation of polymer molecular weight or exposure of the composition to elevated temperatures. The materials are typically agitated until uniform and then packaged in commonly available packaging and sent to storage before distribution.
The liquid materials of the invention can be adapted to a solid block rinse by incorporating into the composition a casting agent. Typically organic and inorganic solidifying materials can be used to render the composition solid. Preferably organic materials are used because inorganic compositions tend to promote spotting in a rinse cycle. The most preferred casting agents are polyethylene glycol and an inclusion complex comprising urea and a nonionic polyethylene or polypropylene oxide polymer. Polyethylene glycols (PEG) are used in melt type solidification processing by uniformly blending the sheeting agent and other components with PEG at a temperature above the melting point of the PEG and cooling the uniform mixture. An inclusion complex solidifying scheme is set forth in Morganson et al., U.S. Pat. No. 4,647,258.
The organic nature of the rinse agents of the invention can be subject to decomposition and microbial attack. Preferred stabilizers that can limit oxidative decomposition or microbial attack include food grade stabilizers, food grade antioxidants, etc. Most preferred materials for use in stabilizing the compositions of the invention include C 1-10 mono, di- and tricarboxylic acid compounds. Preferred examples of such acids include acetic acid, citric acid, lactic, tartaric, malic, fumaric, sorbic, benzoic, etc.
Optional ingredients which can be included in the rinse agents of the invention in conventional levels for use include solvents, processing aids, corrosion inhibitors, dyes, fillers, optical brighteners, germicides, pH adjusting agents (monoethanol amine, sodium carbonate, sodium hydroxide, hydrochloride acid, phosphoric acid, etc.), bleaches, bleach activators, perfumes and the like.
The range of actives in the solid and liquid concentrate compositions of the invention are set forth in Table I and the ranges in the aqueous rinse in Table II.
TABLE I______________________________________ Preferred (wt-%)Actives Useful (wt-%) Liquid Solid______________________________________Hydrocarbon surfactant 2-90 8-30 5-75Fluorocarbon surfactant 0.1-10 0.5-5 0.5-5Siloxane surfactant 0.1-10 0.5-5 0.5-5______________________________________
TABLE II______________________________________Actives Useful (ppm) Preferred (ppm)______________________________________Hydrocarbon surfactant 2-100 30-50Fluorocarbon surfactant 0.01-10 0.1-1.0Siloxane surfactant 0.01-10 0.1-1.0______________________________________
Liquid rinse agents of the invention are typically dispensed by incorporating compatible packaging containing the liquid material into a dispenser adapted to diluting the liquid with water to a final use concentration wherein the active material is present in the aqueous rinse as shown in Table II above in parts per million parts of the aqueous rinse. Examples of dispensers for the liquid rinse agent of the invention are DRYMASTER-P sold by Ecolab Inc., St. Paul, Minn.
Solid block products may be conveniently dispensed by inserting a solid block material in a container or with no enclosure into a spray-type dispenser such as the volume SOL-ET controlled ECOTEMP Rinse Injection Cylinder system manufactured by Ecolab Inc., St. Paul, Minn. Such a dispenser cooperates with a warewashing machine in the rinse cycle. When demanded by the machine, the dispenser directs a spray of water onto the solid block of rinse agent which effectively dissolves a portion of the block creating a concentrated aqueous rinse solution which is then fed directly into the rinse water forming the aqueous rinse. The aqueous rinse is then contacted with the dishes to affect a complete rinse. This dispenser and other similar dispensers are capable of controlling the effective concentration of the active block copolymer and the additives in the aqueous rinse by measuring the volume of material dispensed, the actual concentration of the material in the rinse water (an electrolyte measured with an electrode) or by measuring the time of the spray on the solid block.
The following examples and data further illustrate the practice of the invention. These should not be taken as limiting the invention and contain the best mode.
EXAMPLE I
The following four liquid formulations were prepared by routine mixing of the ingredients.
______________________________________ Formula No.Item Raw Material 1 2 3 4______________________________________1 EO/PO Block Termin- 19.300 19.720 19.633 19.461ated with PO (32% EO)2 EO/PO Block Termin- 52.309 54.147 53.908 53.436ated with PO (39% EO)3 Fluorad ™ FC-170C 0.887 0.8754 Silwet ® L-77* 1.325 1.3135 C.sub.14-15 linear primary 5.000 5.067 5.044 5.000alcohol ethoxylate6 Inerts to 100%______________________________________ *Siloxane of the formula described above where Z is methyl, n is 0, m is and the weight ratio in % of EO:PO is 100:0.
These formulations were evaluated in a modified Champion 1 KAB dishwash machine modified to replace the front stainless panel with a glass window and to conduct rinsing tests using the machine pump and wash arms.
The test procedure is first to select appropriate test substrates to evaluate the test formulations. These substrates are typical pieces of plasticware commonly used in institutional accounts. In preparation for the sheeting test, the test substrates are conditioned with 0.2% Hotpoint soil in softened water at 160° F. for three minutes in the modified Champion 1 KAB dishmachine. The test procedure is to add test rinse aid in increments of 10 ppm actives, to the machine pump, circulate the test solution at 160° F. for 30 seconds, turn off the machine and observe the type of water break on each test substrate. There are three types of water break. These are:
1. No Sheeting. The test solution runs off the test substrate leaving discrete droplets behind.
2. Pinhole Sheeting. The test solution drains off of the test substrate to leave a continuous film. The film contains pinholes on the surface of the film. No droplets remain on the test substrate after the film drains and dries.
3. Complete Sheeting. The test solution drains off the test substrate to leave a continuous film with no pinholes. No droplets remain on the test substrate after the film drains and dries.
The type of water used in this test is softened well water. After each evaluation of test rinse aid per 10 ppm active increment, the results are recorded for each test substrate. The test continues until a good performance profile is obtained that allows a judgment to be made regarding the relative performance of the test formulations.
Results are given below in table form for each of the four formulations noted above.
Tables 1-4
Table 1 contains results for a commercially available rinse aid. Note that none of the plastic substrates exhibit complete sheeting until 70 ppm actives are used.
Table 2 contains results for the same set of actives containing Fluorad™ FC-170C. It performs marginally better at 60 ppm to complete sheet on some of the plastic substrates.
Table 3 contains results for the same set of actives containing Silwet® L-77. It also performs marginally better at 60 ppm to complete sheet on some of the plastic substrates.
Table 4 contains results for the invention. This contains both Silwet® L-77 and Fluorad™ FC-170C. It performs much better at 40 ppm to complete sheet on several of the plastic substrates.
The invention represented as Formulation 4 was also evaluated in four institutional test accounts relative to the commercially available rinse aid represented as Formulation 1. In each account at either the same or even at a lower concentration, there has been a significant improvement in drying results on plasticware. With the commercially available product large residual droplets of rinse water remained on the plasticware so that the dry time was much too long, i.e., the plasticware was stacked wet. With the invention, the dry time was greatly reduced and the plasticware was stacked dry.
TABLE 1__________________________________________________________________________Formula 1Soft water, 160° F., Hotpoint Soiled Dishes. (--) no sheeting,(|) pinholesheeting, (X) complete sheeting.Parts Per MillionActives 0 10 20 30 40 50 60 70 80 90 100__________________________________________________________________________PC Bowl -- -- -- -- -- -- | X X X XPC Tile -- -- -- -- -- -- | | X X XGlass -- -- -- -- | | | X X X XChina Plate -- -- -- -- -- | | | | X XMel Plate -- -- -- -- -- | | X X X XP3 Plate -- -- -- -- -- | | X X X XP3 Cup -- -- -- -- | | | X X X XDnx Cup -- -- -- -- -- | | X X X XDnx Bowl -- -- -- -- -- | | X X X XP3 Jug -- -- -- -- -- | | | | | |Poly Try -- -- -- -- | | | X X X XPS (dish) -- -- -- -- -- -- | | | X XPS Spoon -- -- -- -- -- -- | | | | XSS Knife -- -- -- -- -- | X X X X XTemp °F. 160 160 160 160 160 160 160 160 160 160 160Foam " 0 0 0 0 0 0 0 0 0 0.2 0.3__________________________________________________________________________
TABLE 2__________________________________________________________________________Formula 2Formula 1 with FC-170-C and no Silwet ® L-77Soft water, 160° F., Hotpoint Soiled Dishes. (--) no sheeting,(|) pinholesheeting, (X) complete sheeting.Parts Per MillionActives 0 10 20 30 40 50 60 70 80 90 100__________________________________________________________________________PC Bowl -- -- -- -- -- -- | | | | XPC Tile -- -- -- -- -- -- -- | | | XGlass -- -- -- -- -- | | X X X XChina Plate -- -- -- -- -- | | X X X XMel Plate -- -- -- -- -- | | X X X XP3 Plate -- -- -- -- -- | | X X X XP3 Cup -- -- -- -- | | X X X X XDnx Cup -- -- -- -- | | X X X X XDnx Bowl -- -- -- -- | | X X X X XP3 Jug -- -- -- -- -- -- | | | | |Poly Try -- -- -- -- -- | X X X X XPS (dish) -- -- -- -- -- -- | | | | |PS Spoon -- -- -- -- -- -- -- | | | |SS Knife -- -- -- -- -- -- -- | X X XTemp °F. 160 160 160 160 160 160 160 160 160 160 160Foam " 0 0 0 0 0 0 0 0 0 0 0__________________________________________________________________________
TABLE 3__________________________________________________________________________Formula 3Formula 1 with Silwet ® L-77 and no FC-170-CSoft water, 160° F., Hotpoint Soiled Dishes. (--) no sheeting,(|) pinholesheeting, (X) complete sheeting.Parts Per MillionActives 0 10 20 30 40 50 60 70 80 90 100__________________________________________________________________________PC Bowl -- -- -- -- -- -- -- | X X XPC Tile -- -- -- -- -- -- -- | | | |Glass -- -- -- -- -- -- | X X X XChina Plate -- -- -- -- -- | | | X X XMel Plate -- -- -- -- -- | | | X X XP3 Plate -- -- -- -- -- | | | X X XP3 Cup -- -- -- -- -- -- | X X X XDnx Cup -- -- -- -- -- | X X X X XDnx Bowl -- -- -- -- -- | X X X X XP3 Jug -- -- -- -- -- -- -- | | | |Poly Try -- -- -- -- -- | | X X X XPS (dish) -- -- -- -- -- -- -- | | | |PS Spoon -- -- -- -- -- -- | | X X XSS Knife -- -- -- -- -- -- | | X X XTemp °F. 160 160 160 159 160 160 160 160 160 161 161Foam " 0 0 0 0 0 0.3 0.3 0.4 0.6 0.8 0.9__________________________________________________________________________
TABLE 4__________________________________________________________________________Formula 4Formula 1 with Silwet ® L-77 and FC-170C.Soft water, 160° F., Hotpoint Soiled Dishes. (--) no sheeting,(|) pinholesheeting, (X) complete sheeting.Parts Per MillionActives 0 10 20 30 40 50 60 70 80 90 100__________________________________________________________________________PC Bowl -- -- -- -- X X X X XPC Tile -- -- -- -- | X X X XGlass -- -- -- | X X X X XChina Plate -- | | | X X X X XMel Plate -- -- -- | X X X X XP3 Plate -- -- -- | | | X X XP3 Cup -- -- | | X X X X XDnx Cup -- -- -- -- X X X X XDnx Bowl -- -- -- -- X X X X XP3 Jug -- -- -- -- | | | | |Poly Try -- -- -- | X X X X XPS (dish) -- -- -- -- | X X X XPS Spoon -- -- -- -- | X X X XSS Knife -- -- -- | X X X X XTemp °F. 160 160 160 160 161 161 158 160 161Foam " 0 0 0 0 0.1 0.2 0.4 0.3 0.2__________________________________________________________________________
EXAMPLE II
The following three solid rinse aid formulations were prepared as previously described and compared side by side. Formula 5 contained the same active ingredients as Formula 4 of Example I. The results (Tables 5, 6 and 7) show similar effectiveness as with the Formula 4 compositions.
______________________________________ Formula No. (wt-%)Item Raw Material 5 6 7______________________________________1 EO/PO Block Terminated with 19.649 19.649 19.649PO (32% EO)2 EO/PO Block Terminated with 53.248 53.248 53.248PO (39% EO)3 Fluorad ™ FC-170C 0.875 0.875 0.8754 Silwet ® L-77 1.313B-8852.sup.(a). 1.313B-8863.sup.(b). 1.3137 C.sub.14-15 linear primary 5.000 5.000 5.000alcohol ethoxylate8 Urea 16.000 16.000 16.0009 Inerts to 100%______________________________________ .sup.(a) A siloxane of the formula described above where Z is H and the EO:PO weight ratio in % is 20:80. .sup.(b) A siloxane of the formula described above where Z is H and the EO:PO weight ratio in % is 40:60.
TABLE 5__________________________________________________________________________Formula 5 Parts Per Million 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150__________________________________________________________________________Polycarbonate Tile -- -- -- -- -- -- -- -- -- -- | | | | | |Polycarbonate Bowl -- -- -- -- -- -- -- | | | | | | | | |Glass Tumbler -- -- -- -- -- | | | | | | | | | | |China Plate -- -- -- -- -- -- | | | | | | | | | |Melamine Plate -- -- -- -- | | | | | | | | | | | |Polyproplene Plate -- -- -- -- -- -- | | | | | | | | | |Polyproplene Cup -- -- -- -- -- | | X X X X X X X X XDinex Cup -- -- -- -- -- -- | X X X X X X X X XDinex Bowl -- -- -- -- -- | | X X X X X X X X XPolyproplene Jug -- -- -- -- -- -- | | | | | | | | | |Poly Tray -- -- -- -- -- -- | X X X X X X X X XPolysulfonate Dish -- -- -- -- -- -- -- | | | | | | | | |Polysulfonate Spoon -- -- -- -- -- -- -- | | | | | | | | |Stainless Steel -- -- -- -- -- -- | X X X X X X X X XKnifeTemperature (F) 161 161 161 161 160 160 160 160 160 160 160 160 160 160 160 160Foam (") 0 0 0 0 0 0 0 0.1 0.1 0.2 0.2 0.2 0.3 0.3 0.3 0.3__________________________________________________________________________
TABLE 6__________________________________________________________________________Formula 6 Parts Per Million 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150__________________________________________________________________________Polycarbonate Tile -- -- -- -- -- -- -- -- | -- | | | | | |Polycarbonate Bowl -- -- -- -- -- -- -- | | | | | | | | |Glass Tumbler -- -- -- -- -- -- -- | | | | | | | | |China Plate -- -- -- -- -- -- | | | | | | | | | |Melamine Plate -- -- -- -- -- -- | | | | | | | | | |Polyproplene Plate -- -- -- -- -- | | | | | | | | | | |Polyproplene Cup -- -- -- -- | | | X X X X X X X X XDinex Cup -- -- -- -- | | | X X X X X X X X XDinex Bowl -- -- -- -- | | | X X X X X X X X XPolyproplene Jug -- -- -- -- -- | | | | | | | | | | |Poly Tray -- -- -- -- -- -- -- | | X X X X X X XPolysulfonate Dish -- -- -- -- -- -- | | | | | | | | | |Polysulfonate Spoon -- -- -- -- -- -- | | | | | | | | | |Stainless Steel -- -- -- -- -- -- | | | | | | | X X XKnifeTemperature (F) 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160Foam (") 0 0 0 0 0 0 0 0 0.1 0.1 0.1 0.2 0.2 0.2 0.3 0.3__________________________________________________________________________
TABLE 7__________________________________________________________________________Formula 7 Parts Per Million 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150__________________________________________________________________________Polycarbonate Tile -- -- -- -- -- -- | | | | | | | | | |Polycarbonate Bowl -- -- -- -- -- -- | | | | | | | | | |Glass Tumbler -- -- -- -- -- -- | | | | | | | | | |China Plate -- -- -- -- -- -- | | | | | | | | | |Melamine Plate -- -- -- -- -- | | | | | | | | | | |Polyproplene Plate -- -- -- -- -- | | | | | | | | | | |Polyproplene Cup -- -- -- -- | | | X X X X X X X X XDinex Cup -- -- -- -- | | | X X X X X X X X XDinex Bowl -- -- -- -- | | | X X X X X X X X XPolyproplene Jug -- -- -- -- -- | | | | | | | | | | |Poly Tray -- -- -- -- -- -- | | X X X X X X X XPolysulfonate Dish -- -- -- -- -- -- | | | | | | | | | |Polysulfonate Spoon -- -- -- -- -- -- | | | | | | | | | |Stainless Steel -- -- -- -- -- -- | | | | | | | X X XKnifeTemperature (F) 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160Foam (") 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0__________________________________________________________________________
TABLE 8______________________________________A Key to the Dishware Substrates used for the Plastic RinseAdditive Sheeting TestAbbreviated Title Type of Dishware______________________________________PC Tile Polycarbonate TilePC Bowl Polycarbonate BowlGlass Glass TumblerChina Plt China PlateMel Plt Melamine PlateP3 Plt Polypropylene PlateP3 Plt Polypropylene CupDnx Cup Filled Polypropylene CupDnx Bowl Filled Polypropylene BowlP3 Jug Polypropylene JugPoly Try Polyester Resin TrayPS (dish) Polysulfone DishPS Spoon Polysulfone SpoonSS Knife Stainless Steel Knife______________________________________
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A method for cleaning plasticware wherein the rinse cycle employs a rinse aid composition requires lower concentration of conventional hydrocarbon surfactants, exhibits adequate sheeting on the plasticware and acceptable drying time which prior rinse aids have failed to provide without special handling. The compositions contain hydrocarbon surfactants and a combination of a fluorinated hydrocarbon surfactant and a polyalkylene oxide-modified polydimethylsiloxane surfactant. The composition may be formulated as a solid or liquid suitable for dilution to form an aqueous rinse used to contact the plasticware in a warewashing machine.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] Pursuant to 35 U.S.C. §119(e), this application claims the benefit of the priority to U.S. Provisional Patent Application No. 61/657,069, filed Jun. 8, 2012. The content of the prior application is incorporated herein by its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a process for preparing 4-borono- L -phenylalanine ( L -BPA), particularly to a process that is timesaving, efficient, cost effective and environmentally friendly.
[0004] 2. Description of the Prior Arts
[0005] 4-borono- L -phenylalanine ( L -BPA) is an important boronated compound known to be useful for treatment of cancer through boron neutron capture therapy (BNCT). Therefore, many syntheses of L -BPA have been developed.
[0006] As shown in formula A, two synthesis approaches of L-BPA including formation (a) and formation (b) have been developed.
[0000]
[0007] The approach demonstrated as formation (a) is by introduction of boronic acid group into phenylalanine, which is based on forming the C—B bond directly by the introduction of the dihydroxylboryl substituent to the phenylalanine fragment. J. Org. Chem. 1998, 63, 8019 discloses a process undergoing palladium-catalyzed cross-coupling between an amine-protected L -4-iodophenylalanine, such as (S)—N-Boc-4-iodophenylalanine, and a diboron compound, such as bis-(pinacolato)diboron. L -BPA is then obtained after removal of the protecting group of amine and boronic acid of the phenylalanine. However, an additional pre-process is further required for preparing the boronating agent, resulting in more time consumption and complicacy of the process, and thereby failing to prepare L -BPA in high yield. The prior art discloses that the carboxylic acid of (S)—N-Boc-4-iodophenylalanine reactant is protected into benzyl ester to improve the yield of the obtained protected L -BPA up to 88%. However, an additional step of removing the benzyl ester protecting group of the carboxylic acid of the protected L -BPA is further needed, which complicates the synthetic process. Accordingly, the drawbacks of this method also include the additional pre-process for preparing the boronating agent as mentioned above, and further include the time-consuming and multi-step synthesis involving the protection step of the carboxylic acid and the deprotection step of the carboxylic acid afterwards.
[0008] Another approach demonstrated as formation (b) involving coupling reaction between an amino acid and a boron-containing benzyl or benzaldehyde fragment is also developed. Biosci. Biotech. Biochem. 1996, 60, 683 discloses an enantioselective synthesis of L -BPA by coupling cyclic ethers of boronic acid and a chiral derivative from L -valine, wherein the cyclic ethers of boronic acid are prepared from 4-boronobenzylbromide in advance. However, the last synthetic step of the method readily results in undesired racemization of the amino acid. Thus, an enzymatic resolution step, which typically reduces the production yield, is required to obtain optically-pure L -BPA. Accordingly, the drawbacks of this method still include the additional pre-process for preparing the boronating agent, resulting in more time consumption and complicacy of the process, and thereby failing to prepare L -BPA in high yield.
[0009] Besides, 10 B contained in L -BPA is known as the critical factor accumulated in tumor cells and subsequently irradiated with thermal neutron. Thus 10 B renders L -BPA a treatment of cancer through boron neutron capture therapy (BNCT). However, natural boron exists as 19.9% of 10 B isotope and 80.1% of 11 B isotope. Therefore, many researchers have been developing synthetic processes suitable for producing L -BPA, and preferably suitable for producing 10 B-enriched L -BPA.
[0010] As disclosed in J. Org. Chem. 1998, 63, 8019 mentioned above, the conventional methods comprise multi-step syntheses of the boronating agents, which reduce a large amount of 10 B-enriched materials during the process. As a result, the methods are not suitable for producing 10 B-enriched L -BPA.
[0011] As disclosed in Biosci. Biotech. Biochem. 1996, 60, 683 mentioned above, an optically pure L -BPA is not obtained until the enzymatic resolution step, and also the multi-step syntheses of the boronating agent render the transformations of the 10 B-enriched materials during the process. Hence, the conventional method is not suitable for producing 10 B-enriched L -BPA as well.
[0012] Furthermore, Bull. Chem. Soc. Jpn. 2000, 73, 231 discloses a method based on coupling 4-iodo- L -phenylalanine and pinacolborane in the presence of palladium catalyst. However, since the prior art is silent on how to produce 10 B-enriched L -BPA and also 10 B-enriched pinacolborane is not commercially available, the method is not suitable for producing 10 B-enriched L -BPA, either.
[0013] In addition, Synlett. 1996, 167 discloses a method by coupling iodophenylborate and L-serine zinc derivatives. The method involves indispensable pre-preparation of the L-serine zinc derivatives and the pre-preparation of the iodophenylborate, thereby giving a low yield of L -BPA. Besides, the method is still not suitable for producing 10 B-enriched L -BPA, for both 10 B-enriched BI 3 and 1,3-diphenylpropane-1,3-diol adopted in the method are not commercially available.
[0014] To overcome the shortcomings, the present invention provides a process for preparing L -BPA to mitigate or obviate the aforementioned problems.
SUMMARY OF THE INVENTION
[0015] Given that the aforesaid drawbacks of the prior art such as large time consumption, multi-steps and additional pre-process for preparing the boronating agents, the main object of the present invention is to develop a timesaving, efficient, cost effective, and environmentally friendly process for preparing L -BPA without tedious purification. Accordingly, L -BPA prepared by the process of the present invention has high chemical purity and high optical purity.
[0016] Another main objective of the present invention is to develop a process for preparing L - 10 BPA, particularly, a process for preparing L - 10 BPA that is timesaving, efficient, cost effective, environmentally friendly, convenient and without tedious purification. The process in accordance with the present invention is effective in producing L - 10 BPA with high chemical purity, high optical purity and high isotopic purity.
[0017] Another main objective of the present invention is to develop a process both suitable for preparing L -BPA and L - 10 BPA; particularly, a process for preparing both L -BPA and L - 10 BPA that is timesaving, efficient, cost effective, environmentally friendly, convenient and without tedious purification.
[0018] Accordingly, the process in accordance with the present invention comprises steps of:
[0019] reacting N-protected (S)-4-halophenylalanine of formula (I), a boronating agent and an organolithium to obtain a reaction mixture, wherein the reaction mixture comprises N-protected (S)-4-boronophenylalanine of formula (II) and the R group represents a protecting group;
[0000]
[0020] isolating the N-protected (S)-4-boronophenylalanine from the reaction mixture; and
[0021] deprotecting the R group of the N-protected (S)-4-boronophenylalanine to obtain L -BPA.
[0022] According to the present invention, the boronating agent refers to any agent capable of replacing the X group of N-protected (S)-4-halophenylalanine with a boron atom through the step of reacting N-protected (S)-4-halophenylalanine of formula (I), a boronating agent and an organolithium.
[0023] According to the present invention, the boronating agent has any isotopes of boron, such as 11 B, 10 B or a mixture of 11 B and 10 B.
[0024] According to the present invention, the boronating agent having the mixture of 11 B and 10 B has, but not limited to, a 19.9% of 10 B purity.
[0025] According to the present invention, the boronating agent includes, but is not limited to, trialkyl borate. The trialkyl borate includes, but is not limited to, tributyl borate, triethyl borate, trimethyl borate, triisopropyl borate, tripropyl borate, tri-tert-butyl borate and any other suitable trialkyl borate.
[0026] The present invention provides a process for preparing 4-borono- L -phenylalanine with several advantages. First, the present invention is a shortened process comprising a step of reacting N-protected (S)-4-halophenylalanine, a boronating agent and an organolithium to obtain N-protected (S)-4-boronophenylalanine without protecting the carboxylic acid group of N-protected (S)-4-halophenylalanine in advance, and thus deprotection of the carboxylic acid afterwards is no longer necessary. Moreover, the process in accordance with the present invention uses a boronating agent directly, and thus no additional pre-process is required for preparing the boronating agent. Also, with the simplification of process, L -BPA prepared by the process of the present invention has high chemical purity and high optical purity and an excellent overall yield. Hence, the process of the present invention is timesaving, efficient and cost effective.
[0027] Preferably, the X group of the N-protected (S)-4-halophenylalanine of formula (I) is iodide or bromide.
[0028] More preferably, the X group of the N-protected (S)-4-halophenylalanine of formula (I) is iodide.
[0029] Preferably, the R group of the N-protected (S)-4-halophenylalanine of formula (I) and of the N-protected (S)-4-boronophenylalanine of formula (II) is selected from the protecting groups which can be removed by acid consisting of: tert-butoxycarbonyl (t-Boc) group, trityl (Trt) group, 3,5-dimethoxyphenylisopropoxycarbonyl (Ddz) group, 2-(4-Biphenyl)isopropoxycarbonyl (Bpoc) group and 2-nitrophenylsulfenyl (Nps) group.
[0030] More preferably, the R group of the N-protected (S)-4-halophenylalanine of formula (I) and of the N-protected (S)-4-boronophenylalanine of formula (II) is tert-butoxycarbonyl group (t-Boc).
[0031] According to the present invention, the advantages of tert-butoxycarbonyl group are as follows.
[0032] 1. N-Boc-(S)-4-halophenylalanine is solid and thereby is easily handled during the process;
[0033] 2. One of the starting materials of producing N-Boc-(S)-4-halophenylalanine is Di-t-butyl dicarbonate, which is easily accessible and inexpensive, and hence the N-Boc-(S)-4-halophenylalanine thus produced is inexpensive and easily accessible as well;
[0034] 3. After the tert-butoxycarbonyl group is deprotected, the tert-butoxycarbonyl group is decomposed into CO 2 and t-butanol, which are low hazard chemicals, and thus the present invention is safe and involves little hazard chemicals.
[0035] Preferably, the step of reacting N-protected (S)-4-halophenylalanine, a boronating agent and an organolithium to obtain a reaction mixture comprises reacting N-protected (S)-4-halophenylalanine, the boronating agent and the organolithium at a temperature ranging from −50° C. to −100° C.; and more preferably, at a temperature ranging from −70° C. to −100° C.
[0036] Preferably, the equivalent ratio of the boronating agent to the N-protected (S)-4-halophenylalanine ranges from 2 to 5. Preferably, the equivalent ratio of the organolithium to the N-protected (S)-4-halophenylalanine is at least 3. More preferably, the equivalent ratio of the organolithium to the N-protected (S)-4-halophenylalanine ranges from 3 to 10. More preferably, the equivalent ratio of the organolithium to the N-protected (S)-4-halophenylalanine ranges from 3 to 5.
[0037] Preferably, the step of reacting N-protected (S)-4-halophenylalanine, a boronating agent and an organolithium to obtain a reaction mixture includes steps of:
[0038] mixing the N-protected (S)-4-halophenylalanine, a reaction solvent and the boronating agent to obtain a mixed solution;
[0039] adding an inert organic solvent comprising the organolithium into the mixed solution, so as to obtain the reaction mixture.
[0040] According to the present invention, the concentration of the organolithium comprised in the inert organic solvent ranges from, but is not limited to, 1M to 3 M. More preferably, the concentration of the organolithium comprised in the inert organic solvent ranges from, but is not limited to, 1M to 2M.
[0041] Preferably, the step of adding an inert organic solvent comprising the organolithium into the mixed solution, so as to obtain the reaction mixture, comprises adding the inert organic solvent comprising the organolithium at a temperature ranging from −50° C. to −100° C. More preferably, at a temperature ranging from −70° C. to −100° C. More preferably, at a temperature ranging from −70° C. to −85° C.
[0042] More preferably, the step of adding an inert organic solvent comprising the organolithium into the mixed solution, so as to obtain the reaction mixture comprises adding the inert organic solvent comprising the organolithium dropwise into the mixed solution due to the vigorous reaction of the mixed solution and the organolithium. The time of adding the inert organic solvent comprising the organolithium dropwise into the mixed solution depends on, but not limited to, the amount of the inert organic solvent comprising the organolithium, the concentration of the organolithium comprised in the inert organic solvent, and the amount of the mixed solution; for example, when the volume of the mixed solution ranges from 300 mL to 400 mL and the volume of the inert organic solvent comprising the organolithium ranges from 50 mL to 100 mL, the time of adding the organolithium in the inert organic solvent dropwise to the mixed solution is within 2 to 3 hours.
[0043] Since the reaction of the mixed solution and the organolithium is vigorous, the step of mixing the N-protected (S)-4-halophenylalanine, a reaction solvent and the boronating agent to obtain a mixed solution comprises mixing the N-protected (S)-4-halophenylalanine, a reaction solvent and the boronating agent under nitrogen to obtain a mixed solution and the step of adding the inert organic solvent comprising the organolithium solvent into the mixed solution comprises adding the inert organic solvent comprising the organolithium solvent into the mixed solution under nitrogen, so as to obtain the reaction mixture.
[0044] Preferably, the step of isolating the N-protected (S)-4-boronophenylalanine from the reaction mixture includes steps of:
[0045] adding an aqueous solution to the reaction mixture to obtain a first aqueous layer,
[0046] extracting the first aqueous layer with an extractive solvent to obtain a second aqueous layer;
[0047] adjusting the pH value of the second aqueous layer to less than 4 to crystallize the N-protected (S)-4-boronophenylalanine;
[0048] filtering the crystals of the N-protected (S)-4-boronophenylalanine and then drying the crystals of the N-protected (S)-4-boronophenylalanine, so as to obtain the N-protected (S)-4-boronophenylalanine from the second aqueous layer.
[0049] The step of adjusting the pH value of the second aqueous layer to less than 4 to crystallize the N-protected (S)-4-boronophenylalanine includes a step of adjusting the pH value of the second aqueous layer to less than 4 by adding an acidic solution into the second aqueous layer to crystallize the N-protected (S)-4-boronophenylalanine, and more preferably, to adjust the pH of the second aqueous layer to range from 3 to 4.
[0050] Accordingly, the step of isolating the N-protected (S)-4-boronophenylalanine from the reaction mixture of the present invention is simplified and without any tedious purification, thereby successfully obtaining pure N-protected (S)-4-boronophenylalanine. Therefore, the present invention provides a simplified process without tedious purification, thereby avoiding a waste of solvent and silica gel. Thus, the present invention is environmentally friendly.
[0051] Preferably, the step of deprotecting the R group of the N-protected (S)-4-boronophenylalanine to obtain L -BPA includes steps of acidifying a first organic solvent comprising the N-protected (S)-4-boronophenylalanine to deprotect the R group of N-protected (S)-4-boronophenylalanine, so as to obtain L-BPA.
[0052] According to the present invention, the step of acidifying a first organic solvent comprising the N-protected (S)-4-boronophenylalanine to deprotect the R group of N-protected (S)-4-boronophenylalanine includes steps of acidifying a first organic solvent comprising the N-protected (S)-4-boronophenylalanine by adding an acidifying solution to deprotect the R group of N-protected (S)-4-boronophenylalanine, so as to obtain L-BPA.
[0053] According to the present invention, the step of acidifying a first organic solvent comprising the N-protected (S)-4-boronophenylalanine to deprotect the R group of the N-protected (S)-4-boronophenylalanine to obtain L-BPA includes steps of acidifying a first organic solvent comprising the N-protected (S)-4-boronophenylalanine to a pH lower than 3, more preferably, to a pH lower than 1, to deprotect the R group of the N-protected (S)-4-boronophenylalanine, so as to obtain L-BPA.
[0054] Preferably, the step of deprotecting the R group of the N-protected (S)-4-boronophenylalanine to obtain L -BPA includes steps of acidifying a first organic solvent comprising the N-protected (S)-4-boronophenylalanine to deprotect the R group of the N-protected (S)-4-boronophenylalanine to obtain an acidic mixture; adjusting the pH of the acidic mixture above 1 to crystallize L -BPA; and filtering the crystals of L -BPA and then drying the crystals of L -BPA, so as to obtain L -BPA from the acidic mixture.
[0055] More preferably, adjusting the pH of the acidic mixture above 1 to crystallize L -BPA includes adjusting the pH of the acidic mixture within a range from pH 1 to 3; and continuously increasing the pH of the acidic mixture till within a range from pH 5 to 7.4 to crystallize L -BPA. More preferably, adjusting the pH of the acidic mixture above 1 to crystallize L -BPA includes adjusting the pH of the acidic mixture within a range from pH 1 to 3; allowing the acidic mixture to stand for a period of time; and continuously increasing the pH of the acidic mixture till within a range from pH 5 to 7.4 to crystallize L -BPA.
[0056] More preferably, adjusting the pH of the acidic mixture above 1 to crystallize L -BPA includes adjusting the pH of the acidic mixture within a range from pH 1.5; allowing the acidic mixture to stand for a period of time; and continuously increasing the pH of the acidic mixture till to pH 6.2 to crystallize L -BPA.
[0057] According to the present invention, the period of time includes, but is not limited to 0.5 hour and 1 hour, which is for growing more solids of L -BPA.
[0058] Accordingly, the step of deprotecting the R group of the N-protected (S)-4-boronophenylalanine to obtain L -BPA is simplified and without tedious purification, and the obtained L -BPA is with high chemical purity and high optical purity. Therefore, the present invention provides a simplified process without tedious purification, thereby avoiding a waste of solvent and silica gel. Thus, the present invention is environmentally friendly.
[0059] Preferably, the boronating agent has a 10 B purity not less than 98%.
[0060] Preferably, the 4-borono-L-phenylalnine is 4-( 10 B)borono- L -phenylalanine.
[0061] Preferably, the N-protected (S)-4-boronophenylalanine of formula (II) is N-protected(S)-4-( 10 B)boronophenylalanine.
[0062] According to the present invention, the boronating agent includes trialkyl 10 B borate and any other suitable agent containing a 99% of 10 B purity. Trialkyl 10 B borate includes, but is not limited to 10 B(OBu) 3 and 10 B(OMe) 3 . More preferably, the 10 B boronating agent is commercially available.
[0063] The process according to the present invention is also suitable for preparing 4-( 10 B)borono- L -phenylalanine without additional pre-process for preparing the boronating agent. Besides, the present invention provides 4-( 10 B)borono- L -phenylalanine with high chemical purity, with high optical purity, with high isotopic purity and an excellent overall yield due to the shortened and simplified process, and the present invention has the same advantages of being timesaving, efficient, cost effective, without tedious purification, and environmental friendly as mentioned above.
[0064] According to the present invention, the reaction solvent includes, but is not limited to, ether-type solvent and any other suitable organic solvent. The ether-type solvent applicable in the present invention includes, but is not limited to, tetrahydrofuran, 2-methyltetrahydrofuran, ethyl ether, and any other suitable ether-type solvent. More preferably, the reaction solvent is an ether-type solvent. More preferably, the reaction solvent is tetrahydrofuran or 2-methyltetrahydrofuran.
[0065] According to the present invention, the organolithium includes, but is not limited to, n-butyl lithium, tert-butyl lithium, methyl lithium, sec-butyl lithium, phenyl lithium, and any other suitable organolithium.
[0066] According to the present invention, the inert organic solvent refers to organic material in which the organolithium is at least partially soluble and which is chemically inert to the organolithium, the N-protected (S)-4-halophenylalanine of formula (I), and the boronating agent. The inert organic solvent includes, but is not limited to, alkanes, ether-type solvents and any other suitable organic solvent. The alkanes include, but are not limited to, hexanes, heptane, cyclohexane, pentane, and any other suitable alkanes. The ether-type solvents include, but are not limited to, tetrahydrofuran, diethyl ether, diethoxymethane, dibutyl ether, 2-methyltetrahydrofuran and any other suitable ether-type solvents.
[0067] According to the present invention, the extractive solvent refers to any solvent substantially immiscible with water or slightly immiscible with water.
[0068] The extractive solvent includes, but is not limited to, isobutyl alcohol, toluene, n-butyl alcohol, isopropyl acetate, ethyl acetate, and any other suitable extractive solvent.
[0069] According to the present invention, the acidic solution includes, but is not limited to, hydrochloric acid solution and any other suitable acidic solution.
[0070] According to the present invention, the first organic solvent includes, but is not limited to, acetone, tetrahydrofuran, dioxane, and any other suitable organic solvent. More preferably, the first organic solvent is acetone.
[0071] According to the present invention, the acidifying solution includes, but is not limited to, hydrochloric acid in dichloromethane, trifluoroacetic acid in dichloromethane, methanesulfonic acid in dioxane, trimethylsilyl chloride in dichloromethane. More preferably, the acidifying solution is a solution comprising hydrochloric acid.
[0072] Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0073] FIG. 1 is a chemical equation illustrating an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0074] The present invention provides solutions to solve the problems of the conventional processes for preparing L -BPA. A process for preparing L -BPA from (S)—N-Boc-4-iodophenylalanine is provided as a preferred embodiment of (S)—N-Boc-4-halophenylalanine for illustrating but not limiting the scope of the present invention.
[0075] For a better understanding about the technical features of the present invention and its effect, and for implements in accordance with the disclosures of the specification, preferred embodiment, details and figures are further shown as follows.
[0076] The materials and conditions involved in the embodiments of the present invention are:
[0077] (S)—N-Boc-4-iodophenylalanine, with a purity not less than 96.8%.
[0078] The reaction solvent: 2-methyltetrahydrofuran.
[0079] The boronating agent: tributyl borate or 10 B tributyl borate.
[0080] The organolithium is n-butyllithium.
[0081] The inert organic solvent is hexanes.
[0082] The concentration of the organolithium comprised in hexanes is 1.6 M.
[0083] The extractive solvent is isobutyl alcohol.
[0084] The acidic solution is hydrochloric acid.
[0085] The equivalent ratio of the boronating agent to (S)—N-Boc-4-halophenylalanine is 3.5.
[0086] The equivalent ratio of the organolithium to (S)—N-Boc-4-halophenylalanine is 4.25.
[0087] The first organic solvent is acetone.
[0088] The acidifying solution is a solution comprising hydrochloric acid.
[0089] The present invention is environmentally friendly and reduces cost remarkably since 2-methyltetrahydrofuran, isobutyl alcohol and acetone are non-toxic and are environmentally friendly solvent and since 2-methyltetrahydrofuran can be recycled after use.
Embodiment 1
Preparation of (S)—N-Boc-4-boronophenylalanine from (S)—N-Boc-4-iodophenylalanine
[0090] With reference to FIG. 1 , a 1-L, three-necked flask equipped with a mechanical stirrer, a thermometer, and a nitrogen inlet adaptor capped with a rubber septum was charged with 2-methyltetrahydrofuran (150 mL), and followed by (S)—N-Boc-4-iodophenylalanine (10.0 g, 96.8%, 24.7 mmol), stirred to form a solution, and added tributyl borate (21 mL, 17.9 g, 77.8 mmol) to form a mixed solution. The mixed solution was cooled to a temperature ranging from −76° C. to −85° C., and n-butyllithium (1.6 M in hexanes, 68 mL, 109 mmol) was added dropwise to the mixed solution over 2.5 h to form a reaction mixture. After the addition, a quenched sample of the reaction mixture was analyzed by HPLC and the starting (S)—N-Boc-4-iodophenylalanine was found less than 0.5%. The reaction mixture was quenched slowly with 180 mL of cold water over a 30 min period, then allowed to warm to a temperature ranging from 5° C. to 10° C. The resulted mixture was stirred for 10 to 20 minutes, and then was filtered to remove the insoluble material, washed with 20 mL of water, combined the water wash to the filtrate and transferred to a separatory funnel. The basic lower aqueous layer was separated to obtain a first aqueous layer. The first aqueous layer was extracted with isobutyl alcohol, and was separated from the isobutyl alcohol to obtain a second aqueous layer. The temperature of the second aqueous layer was adjusted to 20° C. to 25° C., and the pH of the second aqueous layer was adjusted to 3 to 4 by using 37% of hydrochloric acid. The product (S)—N-Boc-4-boronophenylalanine started to precipitate during this period. The second aqueous layer mixture was stirred for 30 min, the pH of the second aqueous layer mixture was readjusted to 3.0 and the second aqueous layer mixture was stirred for another 2 hours at a temperature ranging from 20 to 25° C. The second aqueous layer mixture was filtered to obtain solid (S)—N-Boc-4-boronophenylalanine, which was washed twice with 20 mL of water and dried in a vacuum oven at 50° C. for a minimum of 5 hours to a loss on drying (LOD) of less than 0.5% to afford 5.1 g of (S)—N-Boc-4-boronophenylalanine as white solid, which was 98.8% pure determined by HPLC. The yield was 66%.
[0091] The melting point, specific rotation, 1 H NMR data, 13 C NMR data, IR data and MS data of the obtained (S)—N-Boc-4-boronophenylalanine are as follows.
[0092] Melting point: 150° C. (decomp.), determined by Electrothermal 9100;
[0093] [α] D 25 :+13.5° (c=0.5, MeOH);
[0094] 1 H NMR (500 MHz, DMSO-d 6 ) δ 8.0 (singlet (s), 2H), 7.7 (doublet (d), J=7.8 Hz, 2H), 7.2 (d, J=7.8 Hz, 2H), 7.0 (d, J=8.4 Hz, 2H), 4.1 (multiplet (m), 1H), 3.0 (doublet of doublets (dd), J=13.8, 4.5 Hz, 1H), 2.8 (dd, J=13.7, 10.3 Hz, 1H), 1.3 (s, 9H);
[0095] 13 C NMR (125 MHz, DMSO-d 6 ) δ 173.63, 155.48, 139.96, 134.06, 131.96, 128.18, 78.13, 55.06, 36.53, 28.19;
[0096] IR(KBr) ν max : 3328, 2979, 1716, 1689, 1537, 1370, 1345, 1332, 1285, 1165, 1040 cm −1 ; and
[0097] ESI (+)-MS m/z=332.0 (M+Na) + .
Preparation of 4-borono- L -phenylalanine (L-BPA) from (S)—N-Boc-4-boronophenylalanine
[0098] A suspension of (S)—N-Boc-4-boronophenylalanine (5.63 g, 98.5% pure, 17.9 mmol) in a mixture of acetone (34 ml) and water (3.8 ml) was stirred and added hydrochloric acid (37%, 3.8 ml) to form an acidic mixture, and the acidic mixture was stirred at 55° C. for 1.5 h. HPLC analysis of the acidic mixture showed the completion of the reaction. The acidic mixture was cooled to room temperature, and the pH of the acidic mixture was adjusted to 1.5 by using sodium hydroxide aqueous solution. The acidic mixture was stirred for 30 min, and the product 4-borono- L -phenylalanine started to precipitate during this period. The pH of the acidic mixture was readjusted to 6.2 by using sodium hydroxide aqueous solution, and the acidic mixture was stirred overnight at room temperature. The acidic mixture was filtered to obtain solid 4-borono- L -phenylalanine. The solid 4-borono- L -phenylalanine was washed with water, then with 50% aqueous acetone, and dried in a vacuum oven at 80° C. for a minimum of 6 hours to constant weight to afford 3.51 g (93.2% yield) of 4-borono- L -phenylalanine with 99.6% pure as white crystals. The obtained 4-borono- L -phenylalanine was analyzed by chiral HPLC, indicating the ratio of L to D isomers to be 100 to 0 (100% enantiometric excess).
[0099] The melting point, specific rotation, 1 H NMR data, 13 C NMR data, IR data and MS data of the obtained L -BPA are as follows.
[0100] Melting point: 275 to 280° C. (decomp.);
[0101] [α] D 25 :−4.7° (c=0.5, 1M HCl);
[0102] 1 H NMR (500 MHz, D 2 O, CF 3 COOD): δ 7.2 (d, J=7.9 Hz, 2H), 6.8 (d, J=8.0 Hz, 2H), 3.9 (dd, J=7.8, 5.7 Hz, 1H), 2.9 (dd, J=14.6, 5.6 Hz, 1H), 2.7 (dd, J=14.6, 7.9 Hz, 1H);
[0103] 13 C NMR (125 MHz, D 2 O, CF 3 COOD): δ 171.81, 137.31, 135.16, 132.42, 129.65, 54.64, 36.32;
[0104] IR(KBr) ν max : 3585, 3148, 3039, 2914, 1636, 1610, 1505, 1411, 1388, 1344, 1080, 714 cm −1 ; and
[0105] LC-ESI (+)-MS (M+Na) + =m/z 232.0.
Embodiment 2
Preparation of (S)—N-Boc-4-( 10 B) boronophenylalanine from (S)—N-Boc-4-iodophenylalanine
[0106] Set up a 3-L, three-necked flask equipped with a mechanical stirrer, a thermometer, and a nitrogen inlet adaptor capped with a rubber septum. Charged the flask with 2-methyltetrahydrofuran (750 mL), followed by (S)—N-Boc-4-iodophenylalanine (50.0 g, 100% pure, 128 mmol), stirred to form a solution, and added tributyl 10 B borate (106 mL, 90.1 g, 393 mmol) to form a mixed solution. The mixed solution was cooled to a temperature ranging from −76° C. to −85° C., and n-butyllithium (1.6 M in hexanes, 375 ml, 600 mmol) was added dropwise to the mixed solution over 3 h to form a reaction mixture.
[0107] After the addition, the reaction mixture was stirred for an additional 0.5 h at −80° C. HPLC analysis of a quenched sample of the reaction mixture showed the starting material (S)—N-Boc-4-iodophenylalanine was less than 0.5%. The reaction mixture was quenched slowly with 900 mL of cold water over 15 to 20 minutes, then allowed to warm to a temperature ranging from 5° C. to 10° C. The resulted mixture was filtered to remove insoluble solid, and 100 mL of water was adopted for transfer and rinse. The obtained filtrate was transferred to a separatory funnel to separate the layers, the basic lower aqueous layer was separated to obtain a first aqueous layer. The first aqueous layer was extracted with isobutyl alcohol and then separated from the isobutyl alcohol to obtain a second aqueous layer.
[0108] The pH of the second aqueous layer was adjusted to 3 to 4 by using 37% hydrochloric acid at a temperature ranging from 20° C. to 25° C., the product (S)—N-Boc-4-( 10 B) boronophenylalanine started to precipitate during this period. The second aqueous layer mixture was stirred for 30 minutes, then the pH of the second aqueous layer mixture was further adjusted to 3.0 and then the second aqueous layer mixture was stirred for another 2 hours. The second aqueous layer mixture was filtered to obtain solid (S)—N-Boc-4-( 10 B) boronophenylalanine, which was then washed twice with water and dried in a vacuum oven at 50° C. for a minimum of 4 hours to an LOD of less than 0.5% to afford 25.8 g of (S)—N-Boc-4-( 10 B) boronophenylalanine as white solid, which was 99.6% pure determined by HPLC. The yield was 65.1%.
[0109] The melting point, specific rotation, 1 H NMR data, 13 C NMR data, IR data and MS data of the obtained (S)—N-Boc-4-( 10 B) boronophenylalanine are as follows.
[0110] Melting point: 150° C. (decomp.);
[0111] [α] D 25 :+14° (c=0.5, MeOH);
[0112] 1 H NMR: (500 MHz, DMSO-d 6 ): δ 8.0 (s, 2H), 7.7 (d, J=7.7 Hz, 2H), 7.2 (d, J=7.6 Hz, 2H), 7.0 (d, J=8.4 Hz, 2H), 4.1 (m, 1H), 3.0 (dd, J=13.8, 4.5 Hz, 1H), 2.8 (dd, J=13.7, 10.3 Hz, 1H), 1.3 (s, 9H);
[0113] 13 C NMR (125 MHz, DMSO-d 6 ) δ 173.63, 155.48, 139.96, 134.06, 131.94, 128.18, 78.13, 55.06, 36.53, 28.19;
[0114] IR (KBr) ν max : 3331, 2979, 1717, 1689, 1537, 1399, 1372, 1365, 1285, 1165, 1045 cm −1 ; and
[0115] HRMS (ESI): calculated for C 14 H 20 10 BNO 6 [M−H] − 307.1420. found 307.1333.
Preparation of 4-( 10 B)borono- L -phenylalanine (L-( 10 B) BPA) from (S)—N-Boc-4-( 10 B)boronophenylalanine
[0116] A suspension of (S)—N-Boc-4-( 10 B) boronophenylalanine (20.5 g, 99.6% pure, 66.2 mmol) in a mixture of acetone (122 ml) and water (14 ml) was stirred at room temperature and added hydrochloric acid (37%, 14 ml) to form an acidic mixture, the acidic mixture was stirred at 55° C. for 1.5 to 2 hours. HPLC analysis of the acidic mixture showed the completion of the reaction. The temperature of the acidic mixture was cooled to room temperature, and the pH of the acidic mixture was adjusted to 1.5 by using sodium hydroxide aqueous solution, 4-( 10 B)borono-L-phenylalanine started to precipitate during this period, and the acidic mixture was stirred for 50 min. The pH of the acidic mixture was readjusted to 6.2 by using sodium hydroxide aqueous solution, and the mixture was stirred for a minimum of 25 minutes at room temperature. The acidic mixture was filtered to obtain solid 4-( 10 B)borono-L-phenylalanine. The solid 4-( 10 B)borono-L-phenylalanine was washed with 50% aqueous acetone, followed by an acetone rinse, dried in a vacuum oven at 80° C. for a minimum of 6 hours to constant weight to afford 13.3 g (96.4% yield) of 4-( 10 B)borono-L-phenylalanine with 99.9% pure as white crystals, and was analyzed by chiral HPLC, indicating the ratio of L to D isomers to be 100 to 0 (100% enantiometric excess).
[0117] The melting point, specific rotation, 1 H NMR data, 13 C NMR data, IR data, ICP-MS data and HRMS data of the obtained L -( 10 B) BPA are as follows.
[0118] Melting point: 275 to 280° C. (decomp.);
[0119] [α] D 25 :−5.4° (c=0.5, 1M HCl);
[0120] 1 H NMR (500 MHz, D 2 O, CF 3 COOD): δ 7.2 (d, J=8.0 Hz, 2H), 6.8 (d, J=8.0 Hz, 2H), 3.9 (dd, J=7.8, 5.7 Hz, 1H), 2.8 (dd, J=14.6, 5.6 Hz, 1H), 2.7 (dd, J=14.6, 7.9 Hz, 1H);
[0121] 13 C NMR: (125 MHz, D 2 O, CF 3 COOD): δ 171.80, 137.31, 135.16, 132.37, 129.65, 54.64, 36.32;
[0122] IR(KBr) ν max : 3585, 3148, 3038, 2923, 1636, 1610, 1507, 1410, 1398, 1345, 1085, 716 cm −1 .
[0123] ICP-MS measurements for 10 B content is higher than 99.4 (w/w %), wherein 10 B is compared to 11 B; and
[0124] HRMS (ESI): calculated for C 9 H 13 10BNO 4 , [M+H] + 209.0974. found 209.0970.
[0125] Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and features of the invention, the disclosure is illustrative only. Changes may be made in the details, 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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Provided is a process for preparing 4-borono- L -phenylalanine, which has steps of: reacting N-protected (S)-4-halophenylalanine of formula (I), a boronating agent and an organolithium to obtain a reaction mixture, wherein the reaction mixture comprises N-protected (S)-4-boronophenylalanine of formula (II) and the R group represents a protecting group;
isolating the N-protected (S)-4-boronophenylalanine from the reaction mixture;
deprotecting the R group of the N-protected (S)-4-boronophenylalanine to obtain L -BPA.
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BACKGROUND OF THE INVENTION
The present invention relates to a new and improved construction of apparatus for measuring the muzzle velocity V o of a projectile fired from a weapon or a gun, especially a sabot projectile. The measuring apparatus is secured to the muzzle or mouth of the weapon barrel and possesses two measuring coils arranged in spaced relationship from one another in such a manner that the measuring coil axes essentially coincide with the lengthwise axis of the weapon barrel.
A measuring apparatus of this type is known to the art, wherein both of the measuring coils are attached by means of a rod-like support at the weapon barrel in such a manner that the projectile departing out of the mouth or muzzle of the weapon barrel travels through both of the measuring coils. Since, however, the sabot of a sabot projectile, during its exit out of the barrel muzzle, immediately detaches from the projectile body or projectile and begins to disintegrate or break-up, the parts of the sabot are propelled against the aforementioned two measuring coils of the apparatus for measuring the muzzle velocity. Such parts of the sabot which are propelled against the measuring coils rebound towards the projectile and degrade the precise trajectory or flight path of the projectile. Additionally, the measurement of the muzzle velocity of the projectile is appreciably impaired or even rendered useless due to the parts of the sabot impacting against the measuring coils.
Prior art constructions of projectile measuring apparatuses have been disclosed in U.S. Pat. No. 2,691,761, granted Oct. 12, 1954, U.S. Pat. No. 3,659,201, granted Apr. 25, 1972, Canadian Pat. No. 950,700, granted July 9, 1974 and British Pat. No. 965,077, published July 29, 1964.
SUMMARY OF THE INVENTION
Therefore, with the foregoing in mind it is a primary object of the present invention to provide a new and improved construction of apparatus for measuring the muzzle velocity of a projectile fired from a weapon in a manner not afflicted with the aforementioned drawbacks and limitations of the prior art constructions heretofore discussed.
Another and more specific object of the present invention aims at the provision of a new and improved construction of a measuring apparatus for measuring the muzzle velocity of a projectile which is not afflicted with the aforementioned drawbacks, and therefore is particularly suitable for measuring the muzzle velocity of sabot projectiles, and wherein the measuring coils are arranged such that no parts of the disintegrating sabot can strike against the measuring coils.
Yet a further significant object of the present invention is to provide an improved construction of muzzle velocity measuring apparatus for projectiles which is relatively simple in construction and design, extremely reliable in operation, not readily subject to breakdown or malfunction, and provides highly accurate and reliable muzzle velocity measurements.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the measuring apparatus of the present development is manifested by the features that it comprises a sleeve member which has essentially the same internal diameter as the weapon barrel and whose outer or external diameter is essentially of the same size as the internal diameter of the measuring coils. These measuring coils are arranged at both opposed ends of the sleeve member. Advantages of the inventive apparatus are realised by virtue of the fact that the muzzle velocity of sabot projectiles can be measured with the same accuracy as other projectiles devoid of any sabot. Further, parts of the disintegrating sabot do not impact against the measuring coils of the measuring apparatus, and the measuring coils are better protected than heretofore was the case from the aggressive propellant gases.
It is also within the teachings of the invention to protect the measuring coils, preferably through the use of sealing rings, against the action of aggressive propellant gases. Further, a muzzle brake, viewed in the direction of firing, preferably is arranged forwardly of the apparatus for the measurement of the muzzle velocity of the projectile, that the parts of this measuring apparatus preferably are interconnected with one another by a bayonet connection or joint and are attached with the aid of threads or the like at the mouth or muzzle of the weapon barrel.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a longitudinal sectional view through an exemplary embodiment of apparatus for the V o -measurement of a projectile fired from a weapon and illustrating part of the weapon barrel; and
FIG. 2 is a further longitudinal sectional view through the arrangement of FIG. 1 in a plane disposed at right angles to the first longitudinal sectional view of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, according to the showing of FIGS. 1 and 2 the inventive V o -measuring apparatus will be seen to be secured to the muzzle or mouth of a weapon barrel 10 which only has been indicated in phantom lines and contains a connection piece or element 11. This connection element 11 is provided with internal threads 12 and can be threaded onto complementary but not particularly illustrated external threads of the weapon barrel 10. A slot 13 at the rear end of the connection element 11 enables securing the connection element 11 upon the weapon barrel 10 against unintentional rotation. At the connection element 11 there is attached with the aid of a bayonet joint or connection 14 or equivalent fastening device a tube or barrel member 15 which preferably is fabricated of steel. Placed internally of this tube or barrel member 15 is a sleeve member 16 formed of a nonmagnetisable material. At both ends of the sleeve member 16 there are arranged internally of the tube 15 a respective electrical measuring coil 17 and 18. Both of the measuring coils 17 and 18 are embedded in a related protective ring member 19 formed of titanium and having a substantially U-shaped cross-sectional configuration. To protect the measuring coils 17 and 18 against the action of the aggressive propellant gases there is further arranged a respective sealing ring 20 at both ends of the sleeve member 16. These sealing rings or seals 20 prevent that propellant gases can penetrate between the sleeve member 16 and the tube or barrel member 15. At the front end of the tube or tube member 15 there is secured with the aid of, for instance, a bayonet connection 21 or equivalent fastening device a muzzle brake 22. This muzzle brake 22 possesses a conical bore 24 and has a number of radial bores 23 through which the propellant gases can escape into the surroundings, and thus, exerts in conventional manner a braking action, i.e. partially takes-up the recoil of the weapon barrel.
According to the illustration of FIG. 2 connection wires 25 of both of the measuring coils 17 and 18 are guided through two sleeves 26 arranged radially with respect to the weapon lengthwise axis. At both of these sleeves 26 there is secured a tube or pipe 27 directed essentially parallel to the weapon axis. Through the tube 27 there are guided the connection wires or lines 25 into a cable 28 which is attached at the rear end of the tube 27 and possesses at its rear end a coupling element 29.
Since the entire measuring apparatus is heated by the hot propellant gas there is beneficially provided a temperature feeler or sensor 30 in the wall of the tube or barrel member 15. A not particularly illustrated connection wire of the temperature feeler 30 is likewise guided through the sleeve member 26 and the tube or pipe 27 into the cable 28.
Having now had the benefit of the description of the exemplary embodiment of measuring apparatus its mode of operation will be now considered and is as follows:
If a sabot projectile moves out of the muzzle of the weapon, such as a cannon barrel 10, into the sleeve member 16 then the sleeve member 16 prevents detachment of the sabot from the projectile or projectile body. The sabot and the projectile body first can separate from one another after departure out of the sleeve member 16 and the muzzle brake 22. However, the measurement of the muzzle velocity V o of the projectile occurs during such time as the projectile is propelled through the sleeve member 16 of the V o -measuring device, i.e. in other words before the sabot detaches from the projectile. Impairment of the V o -measurement by the sabot which is in the process of detaching or has already detached from the projectile, is therefore prevented. When the projectile along with the sabot travels through the first measuring coil 17, then as is well known in this technology there is induced a signal voltage or measuring signal in this measuring coil 17 which is delivered by the connection wire or line 25 to a not particularly illustrated but conventional evaluation device. Upon passage of the projectile through the second measuring coil 18 there is induced in the same manner as was the case for the first measuring coil 17 a second signal voltage or measuring signal which is likewise delivered to the evaluation device by means of the connection wires 25. From the time difference between both of the signals and from the spacing of both measuring coils 17 and 18 from one another it is then possible to compute in conventional manner the velocity with which the projectile moves through both of the measuring coils 17 and 18.
Since the measuring apparatus is heated and elongated by the action of the hot propellant gases the spacing between both of the measuring coils 17 and 18 changes. With the aid of a temperature feeler or sensor 30 it is possible to take into account the temperature-dependent spacing of both measuring coils 17 and 18 during the computation of the muzzle velocity of a projectile.
So that both of the measuring coils 17 and 18 do not turn relative to one another i.e. remain in the desired relative rotational position with respect to one another, there are secured two bolts 31 and 32 or equivalent anti-rotating securing means in the wall of the tube or barrel member 15, these bolts 31 and 32 extending into not particularly referenced bores of the protective rings 19 formed of titanium. This arrangement also facilitates the assembly of the measuring apparatus.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. ACCORDINGLY,
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The measuring apparatus enables measuring the muzzle velocity V o of projectiles, especially sabot projectiles, wherein the sabot disintegrates immediately after departure out of the muzzle of the weapon barrel. For this purpose two measuring coils, by means of which there can be measured the muzzle velocity of the projectiles, are secured to a sleeve member which prevents disintegration of the sabot prior to the V o -measurement.
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BACKGROUND OF THE INVENTION
This invention relates to a method of producing containers, more particularly producing containers from thermoplastic sheet material for packaging purposes. Containers of this kind are especially used for packaging food.
For producing containers of thermoplastic sheet material a molding die is used which is advanced towards and against a heated sheet material which is clamped at its periphery to be in a generally flat state. Conventional molding dies have a raised or projecting peripheral portion and a recessed central portion so that the containers formed thereby will have a recessed bottom. On its bottom side directed towards the sheet material, the molding die has preferably rounded edges, just as on the edge portion of the side walls adjacent the bottom. For shaping the preheated sheet material or foil, the molding die is substantially normally moved towards the sheet material or foil towards a container the shape of which corresponds to the shape of the molding die. Those portions of the sheet material or foil which are first to contact the molding die are cooled by transmission of heat to the molding die the temperature of which is below the temperature of the plastic state of the thermoplastic sheet material. Thus, those portions not contacting the surface of the molding die at the time a first contact is made will be stretched more than other portions. The stretching effect will be maximum at the edges, particularly at any corners to be formed in the container. The edge and corner portions of the containers are thus formed with reduced thickness, and this is undesirable in view of producing stable containers.
OBJECTS OF THE INVENTION
A primary object of the invention is to provide a method and an apparatus for producing containers from thermoplastic sheet material which are substantially free from undesirably stretched and thinned wall portions.
A further object of the invention is to provide a method and an apparatus for producing containers from thermoplastic sheet material having an improved rigidity.
A further object of the invention is to provide a method and an apparatus for producing containers from thermoplastic sheet material using a molding die, the containers having edge and corner portions of appropriate thickness to achieve satisfactory rigidity.
A further object of the invention is to provide a method and an apparatus for producing containers from thermoplastic sheet material which have a substantially uniform wall thickness, not only in the side walls but also in the edge and corner portions.
SUMMARY OF THE INVENTION
In accordance with the invention, containers are produced from a thermoplastic sheet material which is heated to its plastic state. The heated sheet material is clamped at its periphery, and a molding die is advanced against the sheet material for shaping of the same into containers. The molding die has a projecting peripheral portion and/or a recessed central portion directed towards the sheet material. In order to prevent undue stretching of the sheet material in the edge and corner portions of the container to be formed, a cooling air flow is directed against the sheet material at the region thereof adjacent to the peripheral portion of the molding die, i.e. adjacent the corner and edge portions to be formed.
The invention provides an apparatus for performing the method, having a molding die of the above mentioned type and being provided with cooling air flow channels or bores through which the cooling air flow may be directed against the appropriate regions of the sheet material. In addition, the molding die is provided with a venting channel centrally displaced from the cooling air flow channels to draw the cooling air towards the center portion of the bottom of the molding die and finally vent the air to the environment.
In a preferred embodiment, the contacting surface of the molding die is provided with a coating of felt material, and this coating is provided with openings at the locations corresponding to those of the different channels and bores of the molding die.
DESCRIPTION OF PREFERRED EMBODIMENTS
Further advantageous features and objects of the invention will stand out from the following description of examplary embodiments with reference to the drawings, wherein:
FIG. 1 is a schematic perspective view of a packaging machine in which the method is performed;
FIG. 2 is a cross-section of a molding station in the packaging machine of FIG. 1, having a device for performing the method;
FIG. 3 is a perspective view of a molding die and a container molded thereby;
FIG. 4 shows a sectional view similar to FIG. 2, but of another embodiment;
FIG. 5 shows a molding die provided for the embodiment of FIG. 4; and
FIG. 6 shows a sectional view of the embodiment of FIG. 5.
Referring to FIG. 1, a vacuum packaging machine 1 has in succession a molding station 2, a sealing station 3 and a separating station 4 mounted on a machine frame (not shown). In the forming station 2, containers 7 are formed of a packaging material foil or sheet material 6 drawn from a roll 5 of stock material. The containers are then filled and closed by a cover foil in the sealing station. In the separating station, the individual interconnected packages are separated from each other.
FIG. 2 shows the molding station 2 schematically indicated at FIG. 1 in cross-section. It has an upper portion 8 secured on the machine frame (not shown) and a lower portion 11 connected with the machine frame and movable with respect to the upper portion in direction of arrow 10.
The lower portion 11 has an inner space 12 into which molding inserts 13 are inserted, in accordance with the shape of the containers to be formed. The inner space 12 is connected with a vacuum pump through bores 14, 15 provided in the molding inserts of the containers to be formed, particularly at the edge regions and corners, and through connections 16, 17 leading towards the vacuum pumps.
The upper portion is provided with a molding die 18 which may be reciprocated up and down into the inner space 12 of the lower portion and into a retracted position remote therefrom, by a piston cylinder device 20 connected with a casing 19 of the upper portion. As may be best seen from FIG. 3, the molding die has a central portion 21 at its bottom and a peripheral portion 22 raised over or projecting from the central portion. The peripheral portion has the dimension of the shape to be formed by the molding die in a deep-drawing operation. The central portion 21 is recessed with respect to the peripheral portion by an amount sufficient that the foil or sheet material will not contact the surface of the molding die in this region, during the molding operation.
In the central portion, particularly in the corners thereof, bores 23, 24, 25, 26 are provided which, as seen from FIG. 2, are connected with a pressurized air source (not shown) through connecting members 27, 28 provided at the top side of the molding die. Centrally of the central portion 21, a venting bore 29 is provided in the molding die. The connecting members 27, 28 are free to be receiprocated through openings 30, 31 in the casing, and the air escaping through the venting bore 21 may escape to the environment through these openings.
In FIG. 3, the bores 23 through 26 are provided near the corners 32, 33, 34, 35. Preferably, as shown in FIG. 2, they are arranged in the corners and as close as possible to the inner edge 36 surrounding the central portion 21.
As may be seen in the representation of FIG. 2, the outer dimensions of the molding die 18 are somewhat smaller than the dimensions of the hollow space defined by the molding insert 13 and the side walls.
The device operates as follows: The lower portion 11 is first moved by the piston cylinder device 9 downwardly so that a container formed in the preceding operating cycle will be moved out of the molding station. Simultaneously, a new heated and not yet shaped foil portion 37 is introduced into the molding station. The molding die is in its retracted position so that it will not contact the foil portion 37. Subsequently, the lower portion 11 will be moved by the piston cylinder device 9 into the closed position shown in FIG. 2 towards the upper portion, clamping the foil portion 37 at its four sides between the upper and lower portions. During a preceding operating cycle in another part of the molding station, or in an individual heating station, the foil portion 37 had been preheated to its temperature for plastic deformability. After clamping of the foil or sheet material, the molding die 18 is moved by the piston cylinder device 20 in the direction of arrow 38 towards the foil and against the same into the lower portion 11. The molding die 18 will first contact the preheated foil through its peripheral portion 22. The molding die may e.g. be formed of laminated cloth such as sold under the trade name FERROCELL. By contacting the molding die, the portions in contact therewith will immediately transmit heat thereto. As a result, these zones which are somewhat cooled will be less deformed than those over the recessed central portion 21. Upon further pushing the molding die downwardly, those cooled portions will be less stretched, and a particularly heavy stretching of the foil would result over the central portion immediately adjacent the corners 32, 33, 34, 35. In accordance with the invention, when the molding die 18 is pushed down, an air stream is directed against the foil in the corners of the central portion, through the bores 23, 24, 25, 26. This air will flow from the corners towards the center of the central portion and escapes through the venting bore 29. Thus, the foil will be cooled across the central portion adjacent the portion thereof already cooled by contacting the molding die. The limit between the cooled foil and the heated foil which would otherwise be marked, will now be more continuous. The cooling will be maximum in the corners of the central portion thermselves. It decreases towards the center of the central surface. As a result, upon further advancement of the molding die into the lower portion into the end position, although most of the stretching of the foil will occur in the central region, the corner portions (which would be subject to heavy stretching without cooling) will not be stretched more than the other regions, due to the maximum cooling. The temperature of the supplied air and the pressure thereof are adjusted in such a manner that the cooling will be performed to such an extent that the corners will have the same wall thickness as the wall portions of the containers.
When the molding die is moved to its end position in the lower portion, the deep-drawn foil portion 37 is almost applied against the molding insert 13, but it will have somewhat smaller dimensions than the final shape. To this end, by actuating a vacuum pump and generating a vacuum through the connections 16, 17 and the bores 15, 14, the foil will be sucked to the walls of the lower portion to assume the final dimensions. Then, the container will have an essentially stable shape. The molding die will be retracted into the upper portion. Subsequently, the lower portion will be moved downwardly, and the next operating cycle may be begin.
In the embodiment of FIGS. 4 and 5, those features similar to the above enclosed embodiments are indicated by the same numerals. The embodiment of FIGS. 4 and 5 differs from the above disclosed embodiment by the fact that the ends of the bores 23, 24, 25, 26 are displaced from the central zone 21 towards the corners 39, 40, 41, 42 of the molding die 18 so that they lie between the corners 32, 33, 34, 35 of the central portion 21 and the above mentioned corners of the molding die, as best seen in FIG. 5. Further, the surface directed towards the foil portion 37 is covered with a felt coating 43. The shape of the felt coating 43 is adapted to the outer shape of the molding die. In the embodiment of FIGS. 4 and 5, the felt coating 43 is provided with openings 44, 45, 46, 47 at locations corresponding to the bores 23 through 26, so that the air supplied through the connecting members and the bores may escape from the felt. Further, the felt coating 43 is provided with an opening 48 at a location corresponding to the venting bore 29 so that the air is free to escape from the central portion towards the environment through the venting bore 29.
The operation of the device for deep-drawing a foil is the same as disclosed above. The air escaping from the holes 44 through 47 will even come closer to the corners 39 through 42 of the molding die 18 than with the previously described embodiment, and will pass between the felt coating 43 and the foil portion and arrive at the central portion 21 to escape through opening 48 and the venting bore 29. This will result in having a progressive cooling of the progressively deep-drawn foil from the corners towards the central portion. As soon as the foil arrives in the corners, it will be cooled to such an extent that the stretching thereof will not be stronger than in other regions. The felt coating will, on the one hand, prevent the foil from being damaged when passing over the outlet openings 44 through 47 and, on the other hand, provide a certain distribution of the introduced air by the porosity of the felt.
In FIG. 6, only the lower part of the molding die 18 is shown in cross-section similar to FIG. 4. The molding die 18 corresponds to the embodiment of FIGS. 4 and 5. Only the felt coating 43' differs from the previously described felt coating or covering by the fact that no openings 44 through 47 are provided. The air supplied through the bores 23 to 26 will be fed under pressure through the felt cover. Thus, the air will not locally escape from the bores 23 through 26, but rather escape through surface regions from the felt cover. Just as with the previously disclosed embodiment, the air will flow towards the central portion 21 and escape through the opening 48 and the venting bore 29 to the environment.
In the above disclosed embodiment, the cover or coating 43 is made of felt. The thickness of the felt is selected in such a manner that the felt cover will be sufficiently stable and that, on the other hand, the air may sufficiently pass therethrough and be distributed in such a manner that the corner portions are sufficiently cooled. For example, the felt cover may be attached to the molding die by an adhesive. Instead of a felt material the cover or coating may be formed of another material having similar properties.
It should be understood that the present invention is in no way limited to the above disclosed embodiments and that many modifications and improvements may brought thereto without departing from the true spirit of the invention.
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A method of and an apparatus for producing containers from thermoplastic sheet material are disclosed. The sheet material is heated to its plastic state and clamped at its periphery. Then a moulding die is advanced substantially normally towards and against the clamped heated sheet material. The moulding die has a temperature below the temperature of the heated clamped sheet material and is provided with a projecting peripheral portion and/or a recessed central portion directed towards the sheet material. By further advancing the moulding die by a predetermined amount against the sheet material, this is deformed and shaped into the desired container. A cooling air flow is directed against the clamped heated sheet material in a region thereof adjacent to the peripheral portion of the moulding die to avoid reduced wall thickness at the edge and corner regions of the container by excessive stretching of the sheet material. Thus, stable containers of uniform wall thickness may be produced.
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TECHNICAL FIELD
[0001] The present invention relates to a method of searching and presenting electronic information from one or more information sources, said method comprising the steps of:
[0002] presenting one or more choices to a user,
[0003] registering one or more user specified choices,
[0004] using said one or more user specified choices to retrieve one or more references to information from said information sources, and
[0005] providing a search result comprising one or more references to information.
[0006] The present invention also relates to an apparatus for searching and presenting electronic information from one or more information sources, said apparatus comprising:
[0007] presenting means adapted to present one or more choices to a user,
[0008] registering means adapted to register one or more user specified choices,
[0009] retrieving means adapted to retrieve one or more references to information from said information sources using said one or more user specified choices, and
[0010] means adapted to provide a search result comprising one or more references to information.
BACKGROUND AND PROBLEM
[0011] Searching in large collections of electronic information, e.g. the Internet, large Intranets, etc., is normally done by software programs called search engines, which typically have an interface with one or more text boxes so that a user may type text usually in the form of keywords describing what he wants to find information about. The search engine supplies links to information sources or the sources themselves containing the relevant information by searching through indexes or taxonomies, i.e. a hierarchy of related contexts and/or topics.
[0012] Several search engines are available on the Internet today, the best known engines being Yahoo, Alta-Vista, Lycos, etc.
[0013] Searching can generally be described as a transaction oriented type of searching.
[0014] In a transaction oriented type of searching a search is executed as fast as possible and in one transaction only. There are no feedback possibilities and therefore no possibility for a search engine to learn what a specific user of the search engine prefers or is generally interested in for later use. If the user is not satisfied with the result of the search, e.g. because it contained too many or too few hits, the user has to input a new search criterion and start all over again.
[0015] In a typical transaction oriented type of searching the user specifies one or more keywords e.g. combined with Boolean operators like AND, OR and other criteria like closeness of words, use of synonyms, use of phonetics, etc. The search engine uses one optimal sorting algorithm to find the relevant documents/pieces of information that contain the specified keyword(s), and generally presents this information to the user as a long list of links sorted with regard to how well the information/document contains the keyword(s), i.e. typically sorted according to the highest frequency of the appearance of the specified keyword(s) in the documents in accordance with Boolean rules, phonetics, etc., if any.
[0016] All users of the search engine are normally presented with the same standard user interface, i.e. a static user interface, with a text box to specify the keyword(s) and possible Boolean operators and in some cases check boxes representing other possibilities like closeness of words, use of synonyms, use of phonetics or the like. The result of the search is presented in another interface as a list of links to documents containing the specified keyword(s) e.g. sorted as mentioned above. In this way two very different users specifying the same keywords, e.g. safety of cars, will receive exactly the same list of links regardless of whether e.g. one is a potential buyer of a car and the other is a scientist in safety of cars. This gives an often irritating great amount of uninteresting links for both of them.
[0017] After being presented with the result, the user generally only has the option of selecting one of the links to the found documents, thereby leaving the search engine or initiating a new search.
[0018] There is no possibility of returning to the search engine after reviewing the selected document with information about how relevant the user found that particular document or piece of information and why. So it is impossible for the search engine to make a better choice of presenting the search result the next time.
[0019] Another problem of transaction oriented type of searching is that there is no way of determining what the information value of a result is for a user, since the best search result only depends on the best match of the keywords with e.g. a document. For example, if the user specifies the same keyword(s) at two different times and the result is a document saying that the price of oil is increasing, then this document will only have an information value for the user the first time and none the second time.
[0020] Yet another drawback of transaction oriented type of searching is the lacking reference to time. If e.g. the keyword ‘car’ is specified, the corresponding result will always be the same regardless of which prior keywords the user has specified. The user could e.g. have typed Volvo as the last keyword or have shown the greatest interest in Volvo in 75% of all searches related to cars. This knowledge is not available in a search system without a time reference and individuality of the users.
[0021] One way of obtaining individuality in searching in the prior art is by the use of user profiles. An individual user profile is obtained by monitoring and storing the keywords which a user specifies over a period of time and tries to determine one or more trends for that period, thereby trying to be able to predict what a user is interested in the future. Additionally a user profile may be updated to reflect how interesting the user found a particular document, etc.
[0022] However, such a user profile is not very dynamic or flexible, and unless a user very often searches for the same things and uses the same group of keywords again and again, this kind of user profile does not give any advantages, e.g. if a user one day wants to find information about a certain subject and the next day about a completely different subject, e.g. because he has just learned about it or often does not have an actual goal but just wants to be entertained. Also a keyword is specified at two different times, the user profile generally will change meanwhile, so that two different lists would be presented.
[0023] Generally speaking, prior art search engines and user profiles are good at trying to find or re-find documents, which are about the same as the user has shown an interest in before, but they match a query against an already decided and objective topic category in a hierarchy of related categories (sports is parent of ice-hockey, football, soccer, etc.). So the information value of a document in a given topic category is determined by others.
SOLUTIONS
[0024] The object of the present invention is to provide a method which enables a user to perform a search for electronic information from one or more information sources, the method enabling a representation of relations between different types of information and different users.
[0025] This object is achieved by a method of the type mentioned above, said method further comprising
[0026] a context representation for one or more references, and
[0027] a context representation for one or more users, where
[0028] each context representation contains one or more indications representing other contexts with which each is related,
[0029] and in that the method further comprises the steps of:
[0030] presenting the search result to the user in a number of different ways at the same time based on one or more context representations, and
[0031] presenting additional choices relating to the search result based on one or more context representations.
[0032] Hereby, a method is provided where each object, i.e. references to text document, picture, user, etc., has a representation, i.e. context representation, describing the relations between that particular object and other objects. In this way a very simple and useful way of describing the relations of each object is obtained. The relations between two text documents could e.g. be that a user who found one of them interesting would probably find the other interesting as well. So related objects belonging to a given topic could be connected by their context representations. Furthermore it is possible to locate references to information via intermediate objects.
[0033] In general, the context representations comprise all aspects of a collection of information sources, i.e. documents, people using it, user's collections of information, e-mails, etc., and describe relations of and communication with/between people, information, behaviour and individual interests.
[0034] The method focuses on continuation of a search process instead of starting all over again. The method is executed with a continuous interaction between intermediate results and intermediate searches. In this way, a user is always presented with the possibility of searching, results of searching and additional choices relating to the results at the same time. The choices the user makes will lead to other results and choices, as the user continuously selects the choices and information he finds relevant or interesting.
[0035] All objects in the search process, i.e. references to information, users, search processes, subjects, choices, etc., have a context representation which is used to determine a relation between that particular object and one or more other objects.
[0036] For example, a picture of a car could relate positively to an article about cars, news about cars, an article about trains and relate negatively (or not at all) to an article about clothes.
[0037] In this way the method is able to provide and present several related references to information, users, subjects, etc. which may have a potential information value for the user in the ongoing search process.
[0038] The user may be presented with references to information containing a potential information value together with further choices, thereby being able to review some of the presented information. Preferably the user is also presented with a public virtual topic room where other users have located information which they found relevant for that particular topic. The present user also has the possibility of putting one or more references to information in the public virtual topic room for that particular topic for later retrieval by him and others, or continuing the search in the same or a narrower direction, or changing direction completely if the user gets bored.
[0039] In general, it is possible to enhance the search for information by using the context representations, since every type of object can be described, and thereby made searchable, with regard to contents, time, relations, people, communication of people and information like type, topic, link structure, attributes, etc.
[0040] Another object of the invention is to provide easy and fast access to information which interests the user by having a collection of information for each user which is private where the user can collect references to information that he finds interesting.
[0041] This is obtained if the method further comprises the steps of:
[0042] enabling a user to select one or more references to review the information, and
[0043] enabling a user to collect references to information in a collection of information.
[0044] In this way, the user himself may select references to information or information that he finds interesting or relevant during the dynamic and continuous search process for easy access later. After one or more search processes the user gradually builds a private library of references to information of personal interest.
[0045] The method may further comprise:
[0046] the step of modifying one or more context representations on the basis of one or more context representations, and/or
[0047] the step of modifying a context representation is done when a user executes an action on the basis of one or more references to information or executes an action on the basis of one or more different users, and/or
[0048] the step of modifying a context representation is done when the context representation is related with another piece of information or is related with a user.
[0049] In this way, relations/context representations between different objects may change or influence each other.
[0050] Additionally, a dynamic update of the relations between a user and other users and/or between the user and information is possible, so that they may be dynamically updated, as the search process continues, influencing each other, when a user e.g. selects a choice on the basis of an object, reviews information, keeps a reference to another user or information, etc. This gives a very dynamic system which may describe the preferences of the object over time.
[0051] Different information objects may also change their context representation, so that when e.g. a document is located in the virtual topic room by a user, the context representation of the user may influence the context representation of the document.
[0052] This is e.g. used in a situation where two users have mutual interests, which may be defined by their mutual relation, and one of them has a relation to a document, then it is more likely that the other user will also find that particular document interesting, i.e. it would have a potential information value for him as well.
[0053] The dynamic feature of this method also makes it easy to include new objects, since they only have to be assigned a context representation with preferably pre-set relations. The context representation will then gradually change depending on the search processes in which it is involved. In this way the method is able to handle an information domain that changes rapidly and dynamically like an Intranet of a large company or the Internet.
[0054] Another advantage is that the objects and user may dynamically be categorised by their relations to each other and how they interact. This is obtained by updating the context representation/relations for each object, e.g. piece of information, user, search process, etc., when other objects influence/are in contact with this particular object and vice versa. This is done by changing their context representation reflecting the change in their relations.
[0055] For example, a user may be categorised by which information, e.g. documents, chat rooms, other users, topics etc., he refers to in his collection of information/virtual topic room.
[0056] For example, a document may be categorised by which users, other documents, topics, chat rooms, etc. who/which refer to the document and/or use it.
[0057] For example other user virtual rooms may be categorised by the documents they refer to.
[0058] Context representations selectively choose (by definition and/or situation) by which other types of context representations they want to be affected and by what amount. For example a users context representation may only be changed by the context representation of a search process, the context representation of a file only by the context representation of a document, etc.
[0059] This is different from the prior art which categorises e.g. a document by which words it contains, a picture by which patterns it contains, a search process by keywords, etc.
[0060] As the user collects information, he hereby gradually and continuously participates in categorising every object that is part of or is in contact with the ongoing search process in one way or another. Even the search process itself may be categorised. Every object being part of the process has its context representation/its relations changed depending on the other objects with which it comes into contact.
[0061] In other words, a hierarchy of topics may be generated, where each topic has a corresponding virtual topic room, where the users themselves put references to documents, files, pictures, etc. The virtual topic room has a context representation/relations as well which change dynamically in response to the words in the communication in the room, and are affected by the context representations of search processes, users, archives, related topics, etc. which refer to the virtual topic room or are placed within it. Hereby the topics are not static or objective but generated dynamically through contexts. There is provided a great number of context representations which dynamically categorise/relate users and communication in the same manner.
[0062] This categorisation is dynamic and subjective as opposed to a transaction oriented type of searching where keywords are matched against static categories determined by their keywords.
[0063] In a preferred embodiment each object has a unique context representation reflecting the type of the object, i.e. chat-room, document, picture, e-mail, etc.
[0064] In another embodiment only parts of a context representation of a given type can be set to be affected only by at least a part of certain other context representations.
[0065] In another embodiment each context representation comprises a word part, a topic part and an attribute part. Preferably, the word part contains every word of the information domain and the corresponding relative word frequency in the object for each word, i.e. how many times a specific word appears in the object divided by the total number of words. The relative word frequency is a number between 0 and 1.
[0066] The topic part lists every topic of a given hierarchy of topics and for each topic a corresponding probability of that particular topic being related to the ongoing search process/communication.
[0067] The attribute part lists parameters which are similar for each type of object. Each parameter may have different types of values. For example each context representation may contain an attribute that indicates which other context representations are able to influence that particular context representation, in what way it is influenced, and by how much. The exact nature of this attribute varies with the type of object.
[0068] In another embodiment each context representation comprises a first vector and a second vector, where the first vector comprises information on the information referenced by the context representation, and the second vector comprises information on the change of the context representation as a result of its being affected by other context representations.
[0069] The present invention also relates to an apparatus for searching and presenting electronic information from one or more information sources.
[0070] An object of the present invention is to provide an apparatus which enables a user to perform a search for electronic information from one or more information sources, thereby enabling a description of relations between different types of information and different users.
[0071] This object is achieved by an apparatus of the type mentioned initially, said apparatus further comprising processing means comprising:
[0072] a context representation for one or more references, and
[0073] a context representation for one or more users, where
[0074] each context representation contains one or more indications representing other contexts with which each is related,
[0075] and in that the processing means are adapted to:
[0076] present the search result to the user, via said presenting means, in a number of different ways at the same time based on one or more context representations,
[0077] present additional choices relating to the search result based on one or more context representations.
[0078] This gives the same advantages for the same reasons as described previously in relation to the method.
[0079] Other embodiments of the apparatus according to the invention are characterized by the features defined in the dependent claims, which are advantageous for the same reasons as described previously in relation to the method.
[0080] Further, the invention relates to a computer-readable medium whose contents are adapted to cause a computer system to search and present electronic information from one or more information sources, by performing the steps of:
[0081] presenting one or more choices to a user,
[0082] registering one or more user specified choices,
[0083] using said one or more user specified choices to retrieve one or more references to information from said information sources, and
[0084] providing a search result comprising one or more references to information.
[0085] The computer-readable medium according to the invention is characterized in that the medium comprises
[0086] a context representation for one or more references, and
[0087] a context representation for one or more users, where
[0088] each context representation contains one or more indications representing other contexts with which each is related,
[0089] and by further performing the steps of:
[0090] presenting the search result to the user in a number of different ways at the same time based on one or more context representations, and
[0091] presenting additional choices relating to the search result based on one or more context representations.
[0092] Hereby, when a computer is caused to search and present electronic information from one or more information sources,—as a consequence of the contents of a computer-readable medium as described above—the advantages mentioned in connection with the corresponding method and apparatus according to the invention are achieved.
[0093] Finally, the invention relates to a computer program element comprising computer program code means adapted to enable a computer system to search and present electronic information from one or more information sources, by performing the steps of:
[0094] presenting one or more choices to a user,
[0095] registering one or more user specified choices,
[0096] using said one or more user specified choices to retrieve one or more references to information from said information sources, and
[0097] providing a search result comprising one or more references to information.
[0098] The computer program element according to the invention is characterized in that the program element comprises
[0099] a context representation for one or more references, and
[0100] a context representation for one or more users, where
[0101] each context representation contains one or more indications representing other contexts with which each is related,
[0102] and by further performing the steps of:
[0103] presenting the search result to the user in a number of different ways at the same time based on one or more context representations, and
[0104] presenting additional choices relating to the search result based on one or more context representations.
[0105] When a computer program element causes a computer to enable a computer system to search and present electronic information from one or more information sources, as described above, the advantages mentioned in connection with the corresponding method and apparatus according to the invention are achieved.
BRIEF DESCRIPTION OF THE DRAWING
[0106] The present invention will now be described more fully with reference to the drawings, in which
[0107] [0107]FIG. 1 shows a flowchart of one embodiment of the method according to the invention;
[0108] [0108]FIGS. 2A 2 F illustrate the different windows of an exemplary user interface;
[0109] [0109]FIGS. 3A 3 C illustrate different stages of a search process;
[0110] [0110]FIG. 4 illustrates a schematics block diagram of a preferred embodiment of an apparatus according to the present invention;
[0111] [0111]FIG. 5 illustrates an example of how the context representations may be implemented.
DETAILED DESCRIPTION
[0112] [0112]FIG. 1 shows a flowchart of one embodiment of the method according to the invention. In step ( 101 ) the method is initialised. In step ( 102 ) the user is presented with one or more choices. These choices may contain a text box for specifying one or more keywords representing the kind of information in which the user is interested e.g. together with Boolean operators like AND, OR, NOT etc. Additional choices may e.g. be presented in the form of check boxes, lists, pull-down menus, etc. to indicate choices like closeness of words, use of synonyms, use of phonetics, etc. Additionally, help, instructions, tips and other information like e.g. document of the day may be presented to the user.
[0113] The keywords and possible additional choices specified by the user are registered in step ( 103 ) and stored in an appropriate memory, e.g. RAM, hard disk, etc.
[0114] The user specified choices are use in step ( 104 ) to retrieve references to the corresponding information from different information sources, which may include both structured data (e.g. databases) and unstructured data (e.g. the Internet). The retrieved information is preferably references/links to relevant information in a number of information sources or alternatively the relevant information.
[0115] The information is retrieved by using relations between different objects, where an object could be anything contained in the domain being searched and being able to contain any form of information. Examples of objects are:
[0116] documents comprising text, sound, video, and pictures,
[0117] a user,
[0118] a prior collection of information,
[0119] other users' collection of information,
[0120] chat rooms,
[0121] archives,
[0122] news groups,
[0123] services,
[0124] sound,
[0125] video,
[0126] pictures,
[0127] e-mails,
[0128] etc.
[0129] Each object has a context representation defining the preferences of the object and its relations to a number of other objects. For example, each piece of information may have relations to a number of other pieces of information as well as to other users, and the users may have relations to pieces of information and other users. These relations are used to link information and users together who are connected in a number of ways. For example, a relation could exist between a document describing a car and a user who has participated in a chat room where the subject was cars. The document would have a relation to the chat room and the user would have a relation to the chat room because he had participated.
[0130] So a search finding the document describing a car would also return the user and the chat room because of their mutual relations. This gives a higher probability that the returned objects contain information with a higher information value.
[0131] In step ( 105 ) the retrieved references to information are presented to the user. In the prior art this presentation of information is typically done by displaying a list, usually of a great number, of links to the found relevant information e.g. sorted with respect to how well the information contains the user specified keywords in accordance with any specified constraints (Boolean rules, use of phonetics, etc.). This way of presenting information is not very useful if the number of links is very large, e.g. 10,000, and information most relevant to or interesting for the user is halfway down the list.
[0132] According to this invention the presentation of retrieved references to information is preferably done by displaying several windows, where the number of windows may reflect how experienced the user is or may depend on what the user has chosen. The result of the search is shown as one or more lists, dependent on the user's preferences and/or experience, sorted according to different criteria. In this way a user has a better possibility of finding interesting and relevant information faster.
[0133] All the windows will be explained in greater detail in connection with FIGS. 2A 2 F which show an exemplary user interface using this invention.
[0134] Additionally, the user is presented with additional choices and information. This enables a more process oriented way of searching as the user can continue the search based on updated information and thereby be guided through the search process instead of starting all over again if the relevant piece of information was not identified right away. The additional information presented to the user may e.g. be related topics, other users having the same interests, etc. The additional information will be described in greater detail in connection with FIGS. 2A 2 F.
[0135] In step ( 106 ) the user has to decide whether he wants to add one or more references to information that the user finds relevant or interesting to a public virtual topic room, containing references that different users have found relevant for that particular topic. There is a virtual topic room for each topic. The method will suggest a virtual topic room at the beginning of a search process on the basis of what the user specifies.
[0136] The user may also collect information in a private collection of information containing the user's own collected references independent of the specific topic being presented at the time.
[0137] The user continues the search by selecting any of the presented additional choices, and the method jumps to step ( 103 ) where the process of retrieving and presenting information is repeated together with selecting references to the virtual topic room and the presentation of additional choices, thereby better guiding the user to what he is interested in, which may be a refinement of the current search, a related topic or even a completely different area of interest.
[0138] In this way the user helps building a public virtual topic room, adding his subjective information value in a dynamic process. Virtual topic rooms (e.g. for different search processes) together form a hierarchy of virtual topic rooms.
[0139] The method terminates or initiates a whole new search process e.g. for a different topic when the user so chooses. If the user terminates, he will have the choice of continuing the search process the next time he logs on.
[0140] Preferably, the context representation of each object affects/influences all the other objects with which it is in contact during the search process. This ensures a dynamic update of the relations between the objects and their properties.
[0141] In this way a relation is made when a user selects a document, and some of the user's relations to other objects are transferred to the document, and vice versa. The objects react and influence each other by contact. This gives the advantage that knowledge, properties, and attributes of the user is tied to the document, which may be used to determine the potential information value for both the user and other users. The same applies the other way around when knowledge, properties, and attributes of the document are tied to the user, since if the user was interested in this particular document, it is more likely that he is interested in a document showing similar properties or attributes.
[0142] In this way every object of the system is described/categorised via its relations to and its interactions with other objects; for example, a picture may be described/categorised by who uses it and/or refers to it, under which topic in the topic hierarchy is it located, which news groups use it, which documents contain or have a reference to it, etc. These objects themselves, i.e. which user, which topic, which news group, which document, etc., are related to other objects and so on.
[0143] A user may e.g. be categorised by the information, e.g. documents, chat rooms, other users, topics etc., to which the user refers in his private collection of information.
[0144] A document may e.g. be categorised by the users, other documents, topics, chat rooms, etc., which refer to the document and/or use it.
[0145] As the user collects information, he hereby gradually and continuously participates in categorising every object that is part of the ongoing search process in one way or another. Even the search process itself may be categorised. Every object being part of the process has its context representation/relations changed depending on the other objects with which it comes into contact.
[0146] In the process, a virtual topic room is made for each topic which is organised in a hierarchy of topics.
[0147] This categorisation is dynamic and collectively subjective as opposed to a transaction oriented type of searching where keywords are matched against predetermined categories determined by others.
[0148] [0148]FIGS. 2A 2 F illustrate the different windows of an exemplary graphical user interface. The windows will be described separately.
[0149] [0149]FIG. 2A shows a window called topic window for initiating a search process and receiving input during the process. Subject part ( 201 ) shows the most used top categories, i.e. the most general virtual topic rooms, e.g. Home, Recreational, Moral/Life Philosophy, Science, Business, Culture/Art, and Politics. An experienced user can exchange the default virtual topic rooms with customized favourite rooms.
[0150] In the part ( 202 ) a user may specify one or more keywords representing what the user wishes to find information about at an input line ( 203 ) together with other criteria like closeness of words, use of synonyms, use of phonetics, etc, which may be presented in the form of bullets, list boxes or the like. When the user has specified all the criteria, he presses a button ( 204 ) to initiate the search and retrieval of relevant information.
[0151] Another part is the geographical part ( 207 ) which is used to restrict the search to geographical regions.
[0152] In another part ( 208 ) the user specifies the kind of objects (documents, pictures, chat rooms, etc.) to which the user wants references.
[0153] There is also a help button ( 205 ) for getting online help and a button ( 206 ) for starting a whole new search process with a corresponding new suggested virtual topic room.
[0154] In general, any change of settings of the windows may be presented to the user during the search process which may reject or accept the change by a simple dialogue. Preferably, if the user accepts a proposal then more proposals will be made, and if the user rejects then fewer will be made.
[0155] [0155]FIG. 2B shows an Info Window ( 210 ) where information is communicated back to the user regarding the understanding of the present step in the process together with suggestions ( 212 ) to which the user can select an answer, tips ( 213 ), etc. This information is related to the state of the process and different ways of communicating are also adapted to the state of the process.
[0156] Shown is e.g. a pie chart ( 211 ) showing graphical information on the results in this particular state of the process to assist the user. For example the pie chart ( 211 ) could indicate the languages of the referenced information, or could e.g. show the distribution of the information with respect to categories in a hierarchy. Other graphical and text indicators may be used as well.
[0157] The information presented to the user by the pie charts ( 210 , 211 ) emphasises the focus on differences instead of unity, which makes the user able to continue the search process in a direction he finds interesting. That is if many different subjects are listed, at least some of them may interest the user.
[0158] [0158]FIG. 2C shows a Reference Window ( 220 ) where the references to information ( 221 - 222 ) of the search process in this particular state are shown in different ways. In this example, the lists are sorted according to two different types of all the supported types, i.e. documents and news groups. The user may specify interest in references to information on these two types only, but has the possibility of selecting fewer or more types (See FIG. 2A, 208). This sorting according to different criteria enables the user to locate an interesting piece of information faster. The sub window ( 223 ) shows other criteria according to which the search result could be sorted. It is possible to select combinations of criteria from the sub window ( 223 ). Selecting one of these may exchange an existing sub window or expand the Reference Window ( 220 ) to fit another sub window.
[0159] Selecting a reference in the sub window ( 221 , 222 ) will present that particular document, news group, etc. in another window ( 230 shown in FIG. 2D), as will be described later.
[0160] [0160]FIG. 2D shows a Show Reference window ( 230 ) where the information ( 231 ) of a selected reference is shown. This may be a home page on the Internet, Intranet, etc. This window ( 230 ) will always show a specific result regardless of the type of the information, i.e. a chat room, e-mail address, a sound file, etc.
[0161] [0161]FIG. 2E shows a Virtual Topic Room window ( 240 ) where a specific topic is shown, which is a guess of the most relevant one on the basis of the ongoing search process, or is a topic specified by the user. The user can always select related topics in the list boxes 241 and thereby navigate in the topic hierarchy. The virtual topic room looks very different depending on which topic is currently shown. This room is collectively made by all the users, and in this example the following services are shown: User Tips ( 242 ), Calendar ( 243 ), Agent ( 244 ) for the current topic, Online Store ( 245 ), Online Help ( 246 ), all related to the current topic.
[0162] [0162]FIG. 2F shows a Personal Organiser window ( 250 ) where personal services such as e-mail ( 251 ), Personalised Agent ( 252 ), Personal Calendar ( 253 ), Private Chat-Room ( 254 ) are shown. An Information Organiser window ( 255 ) is also shown where quick access to different types of personal information can be obtained. By selecting Documents an overview of the personal documents is shown, which can be viewed, edited, etc. Similar functions are shown for News, Chat rooms, e-mail addresses, Encyclopaedias, News groups, Services, Tools, Sound, and Pictures. It is in this window the user may place references to information that the user wishes to keep for later use.
[0163] The user interface shown in FIGS. 2A 2 F is just one way in which the communication between the user and the search engine could be provided. Other interfaces of another graphical appearance may be used just as well without leaving the scope of protection of the present invention, as set out in the claims.
[0164] [0164]FIGS. 3A 3 C illustrate different stages of a search process.
[0165] [0165]FIG. 3A shows the beginning of a search process. Shown is a ‘Cockpit’ ( 301 ) forming the frame of the search process. Different menus ( 302 ) give direct access to different windows of information, presentation and choices. A tool bar ( 303 ) presents different icons for initiating different actions.
[0166] The user is presented with few windows at first, and when the user selects one or more choices new windows appear. The complexity and number of windows presented to the user is always under the user's control. Shown are three windows ( 304 , 305 , 306 ). The search window ( 304 ) is where the user can specify what he wants information about. The user can e.g. specify keywords at the input box ( 308 ). In the part ( 307 ) the user can choose a main category/subject where the user presumes the information is to be found. Additionally, an introduction to how the system works and what it can be used for may be given by pressing a button ( 309 ). A ‘Personal Butler’ can be activated by pressing a button ( 310 ) which, on the basis of user tests, can give answers to the most frequently asked questions, give tips, suggestions and guide the user.
[0167] The ‘Information’ window ( 305 ) continuously shows how the system interprets the user's selections and choices. First it is shown how the system/‘Cockpit’ works. It is in the ‘Information’ window ( 305 ) that all feedback to the user is presented on the basis of the user's choices. This gives the user a possibility of understanding how the system interprets the user's behaviour.
[0168] The last window, the ‘Show Reference’ ( 306 ) window, shows a document of the day which is e.g. an often visited and popular document on the Internet or the Intranet. This tells the user that the cockpit ( 301 ) does not disappear when the user selects a reference to information.
[0169] [0169]FIG. 3B shows the cockpit ( 301 ) after the user has e.g. reviewed the demonstration course and been playing a little with the options and possibilities of the cockpit ( 301 ). The user has been presented with choices and selected to have a private ‘Personal Organiser’ window ( 312 ) (See FIG. 2F) added as well as two extra buttons in the ‘Search’ window ( 304 ). One button ( 315 ) to step one step back in the search process if the user has made a choice by mistake or regrets the last action and one button ( 316 ) to indicate great dissatisfaction with the presented references.
[0170] As an example the user has typed ‘Fishing Trip’ in the ‘Search’ Window ( 304 ) and pressed an ‘OK’ button ( 317 ). The Cockpit ( 301 ) suggests to the user that he should continue the search process in the virtual topic room ‘Angling’, where also related topics will be available.
[0171] Additionally, seven documents are shown in a ‘Reference’ window ( 311 ), which are seven documents most recommended by anglers. The most recommended one is displayed in the ‘Show Reference’ ( 306 ) window. If the user is not satisfied with being referenced to angling, the user may press the dissatisfaction button ( 316 ) or choose other criteria in the ‘Reference’ window ( 311 ) by selecting one or more of the proposed criteria ( 314 ).
[0172] Shown are five criteria:
[0173] Other Anglers,
[0174] New documents,
[0175] Number of links,
[0176] The word “fishing trip”,
[0177] Other criteria.
[0178] Potentially new references appear in the ‘Reference’ window ( 311 ) for each combination of criteria. For example, alternative topics/subjects like ‘Leisure Travel’ or ‘Local Leisure’ may be presented if the user deselects ‘Other Anglers’. In this way the search process does not necessarily start all over again when new criteria or topics are selected.
[0179] A virtual topic room ( 313 ) is also presented to the user. This room has references to information that other users have found to relate to ‘Angling’. Presented are other user's tips, events and related information for these events for anglers in the calendar, shops, and people may place advertisements under ‘Buy/Sell’, etc. The virtual topic room ( 313 ) is public and combines use and search by including use patterns in the information system.
[0180] [0180]FIG. 3C shows the Cockpit ( 301 ) for a more advanced user. This user is presented with a greater number of windows, information and choices. The ‘Search’ window ( 304 ) has been expanded by many sub windows containing additional choices like geographical delimitation, the types of objects to which the user wishes references, etc.
[0181] The user's private ‘Personal Organiser’ ( 312 ) also contains a library of references to information that the user has chosen to be interesting during the search process.
[0182] The ‘Reference’ window ( 311 ) now shows two lists of interesting references to information to two different types of objects, in this example ‘Documents’ and ‘Chatrooms’. The user has selected two (shown in bold in ( 311 )) criteria according to which the two lists are sorted.
[0183] A main difference is that although an average user and an expert user specifies the same keyword, e.g. ‘Fishing Trip’, they are treated differently both with respect to the contents of the references and the windows, choices, etc., not only because they have searched for different things earlier but because they are in a different course of their search process.
[0184] [0184]FIG. 4 illustrates a schematic block diagram of a preferred embodiment of an apparatus ( 400 ) according to the present invention. The figure shows processing means ( 403 ) which may be any type of CPU. The processing means ( 403 ) are connected to retrieving means ( 401 ), e.g. a modem, network card, serial cable, etc., which are responsible for communication with other computers via e.g. the Internet. The processing means ( 403 ) are also connected to storing means ( 405 ) for storage and later retrieval of results, variables, etc. The storing means ( 405 ) may be any type of RAM, hard disk, etc. (preferably a combination). The processing means are also connected to presenting means ( 402 ), e.g. a display, for displaying information, choices, results, etc. to a user. Registering means ( 404 ) are connected to the processing means ( 403 ) and provide input from the user, e.g. selection of choices, keywords, etc., by mouse and keyboard or the like.
[0185] The processing means ( 403 ) are responsible for the execution of a program which enables a user to search for various information in a continuous, dynamic search process, as described in connection with FIG. 2.
[0186] This is done by letting each object, i.e. information, user, search process, etc., have a context representation that defines the relation between a particular object and one or more of all the other objects. For example, to link information and a user or information and other information together.
[0187] The relations are built dynamically as the search process proceeds, since objects coming into contact with each other may change their relations, i.e. affect the others' context representation. Preferably, each type of object has a unique context representation, which has its unique rules, e.g. defining which types of objects/context representation it is allowed to change/affect and how, by how much, etc.
[0188] A user is presented with many types of information at the same time. Via the relations the search engine may provide information which has a potential information value for the user, as described before.
[0189] The user has to decide whether he wants to add one or more relevant or interesting references to information to his collection of information, which is a virtual topic room containing all the users' own references to that particular subject and/or search process.
[0190] In this way a user helps building a virtual topic room representing his subjective information value in a dynamic process by communicating with the apparatus ( 400 ). Virtual topic rooms (e.g. for different search processes) together form a hierarchy of virtual topic rooms.
[0191] As the user collects information, he hereby gradually and continuously participates in categorising every object that is part of the ongoing search process in one way or another, since his context representation changes the context representation of the information with which he is in touch. Even a search process itself may be categorised. Every object being part of the process has its context representation/its relations changed dependent on the other objects with which it comes into contact.
[0192] [0192]FIG. 5 illustrates an example of how the context representations may be implemented. As described earlier, each type of object of the information domain has a unique type of context representation.
[0193] Shown is a context representation ( 500 ) which is formed by two main parts, i.e. a first main part ( 501 ), denoted ‘S’, describing the properties of the original, and a second main part ( 502 ), denoted ‘D’, describing the properties of the object as a result of the dynamic changes arising from contact with other objects. The first main part ( 501 ) is static, and the second main part ( 502 ) changes dynamically as the object gets into contact with other objects.
[0194] But if the document was created by a user who also has a context representation ( 500 ), then the user's D-part influences the D-part of the document according to the attributes (S, Attributes). Additionally, the D-part of the document will also influence the user's D-part if the attributes of the user allow it.
[0195] For example, a context representation of a document may change/be influenced, if a user sends the document to another user, by the other user's context representation, and vice versa. Furthermore, the two users' context representations may influence each other.
[0196] A hierarchy of topics is created according to which all objects can be categorized. The hierarchy may be dynamic by letting each topic be a virtual topic room, where the users themselves may locate references to documents and other objects. A topic itself is an object with a context representation which is dynamically influenced by what the users locate in the virtual room. All other objects, which are not located by users, can hereby dynamically obtain their topic part on the basis of how much they resemble the context representation of a virtual topic room.
[0197] Each main part ( 501 , 502 ) is divided into subparts; a type part ( 503 ), a contents part ( 504 ), a topic part ( 505 ), a link part ( 506 ), and an attribute part ( 507 ).
[0198] The type part ( 503 ) contains the actual type of the object, e.g. documents, sound, video, and pictures, a user, a prior collection of information, other users' collections of information, chat rooms, news groups, services, archives, e-mails, etc.
[0199] The contents part ( 504 ) contains information relevant to the contents of a given object, the contents part of a text document may contain words from the title, headlines, stressed/quoted sections, specialised and technical words which are meaningful and/or particularly interesting.
[0200] The actual contents of an object are typically analysed to derive additional information like object type, date, author, topics and linking to other objects.
[0201] Matching actual contents between two different objects is typically a matter comparison in its simplest form. A refinement often used to further enhance quality is the allowance of fuzzyness in the search terms and the contents matched. To compensate for spelling or typing errors, dictionaries or phonetic match algorithms can be consulted. Neural networks, etc. are utilized in image and sound recognition in a similar fashion.
[0202] The topic part ( 505 ) lists every topic of a given hierarchy of topics and for each topic a corresponding probability of that particular topic being related to the ongoing search process/communication.
[0203] The topics of an object are not easily determined. This is often done manually by a human. Libraries have for example devised category systems by which books are categorized, and Internet directories like Yahoo! have a category tree, i.e. a taxonomy, by which Internet links are ordered.
[0204] A topic in a taxonomy tree describes the contents of objects in a generalized context. The taxonomy tree in itself thereby describes topics in the context of other topics with respect to generalized or specialized placement, e.g. football is specialized from sport, Art is generalized from Van Gogh. The taxonomy is not restricted to a tree, but is best described by a directed graph.
[0205] An object can have significance/informational value for multiple topics at the same time. The distribution of the significance in the taxonomy is distributed generally in three patterns. The three patterns can easily coexist for the same object, but each pattern identified can be intelligently interpreted. Thus it is interesting to identify patterns for the given objects such as:
[0206] Horizontal topic distribution significance,
[0207] Vertical topic distribution significance,
[0208] Singular topic significance.
[0209] Horizontal topic distribution in a taxonomy graph signifies an object having a general view of a subject area if the horizontal topic distribution is placed near the root of the taxonomy. It will not go into a subject in depth and is hence an object which will give an overview and general knowledge of an area. An example is a document discussing the topic Art from a general perspective, not with any particular time period, form or person in mind or with all of them included in the contents.
[0210] Vertical topic distribution significance in a taxonomy graph signifies an object having a strong relation with a single topic on many levels of detail.
[0211] Singular topic significance in a taxonomy graph signifies an object in a special relation with a topic. It will not broaden the overview to related topics, or seek to generalize or specialize the topic area.
[0212] As mentioned, an object is not confined to have only one pattern of the three ones mentioned above. Each pattern can be combined and occur several times. An example is a document discussing the high tech use of drugs in all areas of modern sports, while going into anabolic steroids and the making of these for muscle fiber building in depth. The document has a horizontal topic distribution significance for modern sport—all this is discussed in general. The document also discusses anabolic steroids, the use and the making of these, and thus it has a vertical topic distribution significance for drugs, anabolic steroids, the use and the making of these.
[0213] Any prior art pattern recognition mechanism can be applied to identify these three patterns after which they may be utilised,
[0214] to give statistics of information coverage for certain topics. For example, which products in a portfolio are not documented in depth for all topic areas? Translated: which topics in the product area do not have documents with vertical topic distribution significance in all branches of specializations?, and
[0215] to find people with certain skill characteristics. For example, who has a general overview of French foreign affairs ? Translated: which person has a horizontal topic distribution significance of the topic French foreign affairs?
[0216] The Link part ( 506 ) contains information regarding the link structure for a given object, e.g. which other objects link to a given object and to which other objects the given object links, and which relations exist between the given object and other objects. For example, an Internet HTML document and other document standards may link to other documents or objects. The link structure can be utilized to analyse numerous aspects from information sources.
[0217] A known method (Kleinberg, IBM) mentions an analysis of links which will locate hubs and authoritative centers in information sources. An information hub is typically an index of links to numerous other objects. Authoritative centers are highly referenced information areas, a single object or a highly interconnected group of objects.
[0218] The analysis of links and relations between objects can be further refined by applying a weight to each link or mathematical edge in a link graph. The weight signifies a propagation weight with which authority is propagated to adjacent objects.
[0219] The link structure can be built using knowledge from for example HTML or XML documents, but other rules for linking can be applied. For persons this could e.g. be derived from frequent communication between groups of persons.
[0220] Besides assigning relative authority to objects, which can be utilized to identify qualified objects, the link structure can be used in data relation analysis to identify information connections for e.g. competition analysis, back tracking of information sources, etc.
[0221] The attribute part ( 507 ) lists parameters which are similar for each type of object. Each parameter may have different types of values. For example each context representation may contain an attribute that indicates which other context representations are able to influence that particular context representation, in what way it is influenced, and by how much. The exact nature of this attribute varies with the type of object. Attributes for objects are simple information by nature. Examples of attributes are contents length, author, languages, dates significant for the object, lix number (readability index), and title may be specified, etc. The matching of attributes is simple and straightforward.
[0222] A dynamic context representation of all objects with type, contents, topics, links and attributes ensures a general and similar description of all actors in an information system. The representation method can then be utilized for matching in an information search system.
[0223] In order to achieve reasonable speed and functionality certain demands must be fulfilled, as will be described in the following.
[0224] The objects demand an architecture which must conceptually model two function areas. An indexing layer to make the objects searchable, and a layer to interpret the processes in an information system.
[0225] The design architecture must meet demands for scaleability since the amount and growth of information is very high today. The number of documents on the Internet is typically measured in billions and the number of users in hundreds of millions, etc.
[0226] The index layer must be able to index all date structures of the object: type, contents, topics, links, and attributes. Each data structure is somewhat different, which demands different types of indexes.
[0227] The type, contents and attributes must be indexed according to a name or a simple textual representation of a type or an attribute. This can be implemented using standard methods of indexing, for example via a standard SQL database solution. The type and the attributes can for example be looked up in a file system or other repositories. The languages used can be extracted by for example using the trigram algorithm. Many more features can be derived and extracted by analysing the contents or getting information from other sources.
[0228] The link structure between objects is very complex and large as well. To build the graph structure and make it ready for indexing, one must solve multiple differential equations with multiple unknown variables. The processed link structure must have identified all authoritive centers and hubs, which must be made searchable through indexing.
[0229] The topic index contains the associated topics for each object. As mentioned, certain patterns must be identified and the identified topics and patters must be made searchable through indexing. A pattern recognition method must be applied and adapted for a solution such as a neural network.
[0230] The layer interprets all behavior in the information system as a process. As discussed earlier, the distinction between a transaction oriented information system and a process oriented system is the key. Examples are
[0231] communication from a user to the system can be seen as one process, i.e. reading documents, searching for news, sending email, etc. It will influence the read information from a document or a news source and it will influence both the user who receives and sends the email, and
[0232] communication in a discussion forum by several persons will influence the object for the discussion forum and it will influence the persons participating.
[0233] The propagation of either part of the parameters of an object to other objects can be done using various statistical methods. The statistical method applied must:
[0234] be capable of modelling temporal state development,
[0235] be aware of distortion and uncertaincy, and
[0236] allow weighing of each parameter to model individual propagation rate of the parameters.
[0237] Both Markov models and Baysian dynamic lineary models can be applied to give a suitable solution.
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The invention relates to a method of searching and presenting electronic information from one or more information sources. The method comprises the steps of:
presenting one or more choices to a user,
registering one or more user specified choices,
using said one or more user specified choices to retrieve one or more references to information from said information sources, and
providing a search result comprising one or more references to information.
The method further comprises:
a context representation for one or more references, and
a context representation for one or more users,
where each context representation contains one or more indications representing other contexts with which each is related,
and the steps of:
presenting the search result to the user in a number of different ways at the same time based on one or more context representations, and
presenting additional choices relating to the search result based on one or more context representations.
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[0001] This application is a continuation in part of and jointly owned by the same assignee as application Ser. No. 12/168,497 filed on Jul. 17, 2008 which claims priority to U.S. provisional application No. 60/950,222, filed Jul. 17, 2007, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to cotton fiber processing and more particularly to an apparatus and method of separating foreign matter from fibrous cotton that has been ginned from the seed. About 60 years ago cotton “lint Cleaners” were introduced into cotton gins in the United States to overcome the dramatic increase of extraneous matter brought to the gins in the seed cotton harvested by the newly introduced mechanical cotton harvesters as compared to the previously customary hand picked (harvested) cotton. These “Saw-type” lint cleaners did indeed greatly improve the appearance of the lint by removing much “trash”, but also by aggressively “combing” the tufts of fibers to diffuse them and hide the remaining fine trash particles. The most successful of these “Saw Type” lint cleaners contained a “Feed Roller” working against a concave “Feed Plate” to compact the lint batt and firmly hold it about 7 mm from the sharp tips of the fine teeth on the lint cleaner cleaning cylinder that plucked the fibers from the batt. These lint cleaners were commercially very successful because they made the lint appear to the naked eye to meet the higher grades in the classing sample standard grade boxes which were the primary determinant of the lint value along with the manually determined “staple length” which also “pulled” somewhat longer by the manual grading or classing systems of the day. Soon two and even three stages of these aggressive lint cleaners were used in series benefitting the farmers, but the results at the textile spinning mills proved disappointing.
[0003] The inadequacy of the manual-visual method of classing lint cotton became apparent, and innovative researchers introduced various cotton quality test instruments that measured spinning qualities that were only vaguely sensed by manual methods, if detected at all. Several of these test instruments were improved to perform fast enough to process lint samples as they were produced during the peak of the ginning season, and they were combined into a classing system referred to as “High Volume Instrumentation” (HVI). HVI systems were officially adopted for commerce in the United States and today HVI systems are being promoted for use around the world. However, there is much inertia in the long standing manual classing systems and the transition to HVI commercial use in many foreign countries may be very gradual.
[0004] As more of these accurate spinning quality tests were made using instrument testing equipment comparing the before and after lint quality through these saw type lint cleaners, it became clear that these lint cleaners were breaking many fibers and producing neps, both of which are very detrimental to yarn quality. The location within these saw type lint cleaners that caused this fiber quality damage was controversial, but it has now been shown that the major damage is caused at the point where the cotton batt is fed to the teeth of the cleaning cylinder.
[0005] Patent application Ser. No. 12/168,497 describes apparatus that reduces fiber damage by eliminating the formation of the cotton tufts into a batt, but rather, individually applies the tufts of cotton as they come from the gin stand in an air stream directly onto the teeth of the lint cleaner cleaning cylinder teeth without mechanically restraining the tufts. This patent application is for use with lint cleaners that have short, densely spaced teeth on a solid cylinder which currently are universally used in the U.S. saw gins on upland cotton.
[0006] Roller ginning in the United States has been almost entirely confined to ginning pima cotton which is more valuable than upland cottons because of its extra long, fine fibers that warrant the slow, more expensive roller ginning process that also breaks fewer fibers than saw ginning. However, the roller ginning process has recently been made much faster until roller ginning speed (Capacity) is now nearing saw ginning capacity per unit width of ginning machine. High speed roller ginning is now being introduced to the ginning of some upland cottons in response to monetary incentives for roller ginned lint. Roller ginned lint is classed on a different system from saw ginned lint. The roller ginned lint classing system has completely different standards for “preparation”. The roller ginned “prep” standard calls for a certain lumpy appearance caused by the roller gin that pulls off much larger tufts from the seed than saw gins. The lint cleaners used with roller gins, therefore, do not as aggressively “comb” the lint to preserve the characteristic lumpy appearance of roller ginned lint. The cleaning cylinders used on roller ginned cotton generally have less densely spaced teeth or even bars or lugs which would not provide an air seal between the cleaning cylinder and the high speed separator cylinder housing as is required in application Ser. No. 12/168,491. Furthermore, the textile industry, over many years has developed several specialized cotton cleaning cylinders, including “Kirschner” and “Buckley” beaters, which have more open designs that would allow air to be drawn through the cleaning cylinder back into the high speed separator housing if the apparatus of Ser. No. 12/168,497 were used. Moreover, the open design cleaning cylinders often are self doffing and therefore they eliminate the doffing cylinder of '497, a considerable initial and maintenance expense. The principle proven benefits of Ser. No. 12/168,497 would be lost for use with these many “open” cleaning cylinders without the added concepts of the present invention.
[0007] Other prior methods and apparatus include those such as illustrated in U.S. Pat. No. 6,088,881, incorporated herein by reference, wherein a revolving perforated drum is used to allow air flow through the drum such that a cleaning cylinder may remove cotton fiber from the perforated drum and carry it past a plurality of cleaning grid bars, thereby separating the air flow and removing foreign matter from the fibers, before the fiber is doffed from the cleaning cylinder for subsequent air flow to downstream processing.
[0008] However, the perforated revolving cylinder of the '881 apparatus, revolving at velocities to prevent agglomeration of the tufts in the air stream, develops centrifugal forces that cause the fine trash and very short fibers that penetrate the perforations to accumulate on the interior surfaces of the perforated cylinder. These accumulations require the use of compressed air blasts to cause them to move axially out the open ends of the cylinder. While the compressed air blasts provide a solution to this problem of accumulations, the maintenance and cost of the compressed air system detracts from the otherwise excellent performance of the apparatus per the '881 patent.
[0009] The quality preserving actions of the methods and apparatus shown in U.S. Pat. No. 6,088,881 and application Ser. No. 12/168,497 would be beneficial for use with all types of lint cleaning cylinders, including those used with roller gins. The improvement described herein provides the solution to combining the benefits of these concepts with cleaning cylinders of most all designs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] An apparatus embodying features of the invention is depicted in the accompanying drawing wherein:
[0011] FIG. 1 is a sectional view of the apparatus disclosed in the copending patent application Ser. No. 12/168,497;
[0012] FIG. 2 is a sectional side elevational view of an embodiment of an apparatus of the present apparatus;
[0013] FIG. 3 is a partial sectional side elevational view of another embodiment of the transfer wheel of the present apparatus.
BRIEF SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to provide an improved method and apparatus for separating foreign matter from tufts of fibrous cotton. A further object of the invention is to allow the high speed separation and cleaning of upland cotton using open cleaning apparatus and a combination air seal with fiber transfer roller.
DETAILED DESCRIPTION OF THE INVENTION
[0015] As shown in FIG. 1 . Patent application Ser. No. 12/168,497 depends upon the short, dense teeth of the standard cleaning cylinders used in upland cotton gin lint cleaners to seal against the air partial vacuum in the housing surrounding the “high speed air separator cylinder”. This vacuum is required to induce an air stream to convey the tufts of lint to the lint cleaner. FIG. 1 taken from patent application '497 illustrates the housing around the sub atmospheric air stream entering at C and exiting at E. It also shows the air seal formed between the short, dense teeth at “ 13 ” and close fitting plate “ 27 ” preventing atmospheric pressure air from the trash removing grid area “ 23 ” being drawn into the incoming air stream C. Plate 28 also fits closely to the tips of the cleaning cylinder teeth to prevent air, coming in at D, from being drawn into the housing around the high speed air separator cylinder.
[0016] An improved apparatus and method according to the present invention is illustrated in FIG. 2 , wherein fiber tufts comingled with foreign matter are pneumatically carried by a conveying air stream C into the apparatus via an air duct 11 as is well known in the art. FIG. 2 is a cross sectional illustration of a preferred embodiment containing most of the features of the present invention. Fiber tufts, commingled with foreign matter, are conveyed into the entry duct 11 of the apparatus by a high speed air stream preferably under sub atmospheric air pressure. Entry duct 11 converges arcuately toward the periphery of high speed air separator cylinder 17 that is pervious to both inward and outward flow of fiber, foreign matter and air. However, the arcuate convergence of duct 11 combined with the high speed arcuate change of direction develops centrifugal forces urging the fiber and foreign matter to move toward the converging surface 14 of duct 11 . Approximately diametrically opposite the point on the separator cylinder where the duct 11 converges against the periphery of the air separator cylinder 17 is a stationary arcuate section of perforated screen 16 closely following the arc of the periphery of separator cylinder 17 . The perforated screen 16 is pervious to air flow there through, but impervious to desirable fiber. Any fiber that collects on the screen is immediately swept away from the screen by a plurality of circumferentially spaced outer surfaces 18 that are spaced apart circumferentially to allow the conveying air and entrained dust and fine foreign matter particles to pass through the screen 16 and exit the apparatus via an air discharge duct 15 at Q. As outer surfaces 18 rotate across perforated surface 16 the surfaces 18 substantially sweep away any accumulations of matter on the stationary separator surface 16 and return any desirable fiber back to the conveying air stream proximal terminal portion 14 of duct 11 . The rotation of revolving outer surfaces 18 is such that the commingled fiber and foreign matter are exposed to the surface 32 of air seal and fiber transfer cylinder 31 while the revolving outer surfaces 18 are rotating toward stationary semi cylindrical surface 16 .
[0017] Up to this point the present invention follows the teachings of patent application Ser. No. 12/168,497 and the preferred embodiment of the present invention likewise follows FIG. 1 of patent application Ser. No. 12/168,497. But from this point on the preferred embodiment of the present invention deviates from patent application Ser. No. 12/168,497 in that it calls for the addition of the air seal and fiber transfer cylinder 31 between the air separator cylinder 17 and the cleaning cylinder 12 as shown in FIG. 2 . As will be understood from the prior art, the rotation of cleaning cylinder 12 carries the tufts past a stripping bar and plurality of cleaning grid bars 23 disposed to separate a major portion of foreign matter from the cotton tufts on the cleaning cylinder 12 , which foreign matter may be disposed via a trash conveyor system for subsequent collection and baling. As noted above, roller ginning is generally used for the higher quality cottons and the lint cleaning machinery often uses longer, more widely spaced pin or lug type cylinders which would not prevent air flow back into the high speed separator section that is under sub atmospheric air pressure.
[0018] Air seal and fiber transfer cylinder 31 is needed for use with such a cleaning cylinder 12 that has longer, less dense teeth or lugs that would allow air to be pulled back from the trash removing grid section into the sub atmosphere air pressure housing around the high speed air separator cylinder 17 . In the present apparatus, as shown in FIG. 2 , cylinders 17 , 31 , and 12 , all revolve counter clockwise and preferably successively at increasing surface speeds. Air seal and fiber transfer cylinder 31 primarily acts as what is generally known as a “vacuum wheel”. To make this air seal, air seal and fiber transfer cylinder 31 must fit tightly against arcuate walls 37 and 36 both on the fiber carrying side and the return side of the cylinder 31 and it must be constructed to prevent air from passing through the air pressure differential across the cylinder at all times in its rotation. Also this cylinder 31 must be capable of carrying the fibers around the arcuate fiber transfer side, preferably while holding the fiber tufts firmly in place as they enter the pinch point between this cylinder and the arcuate wall 37 on the fiber carrying side and hold the tufts until they are released to the tip of a streamer plate 38 at the end of the arcuate wall from which the fibers are pulled by the teeth of cleaning cylinder 12 . Thus, in one embodiment, the surface 32 of air seal and transfer cylinder 31 is of a dense brush type consistency that will engage fibers and present a dense but flexible seal in the interstice between the cylinder 31 and the walls 36 and 37 . Such a brush like surface would preferentially be composed of bristles spaced less than about 6 millimeters apart over the surface of the transfer cylinder.
[0019] The surface of cylinder 31 should preferably be radially flexible and continuous to maintain an air seal at all times both on the lower, fiber exit side and upper return side of cylinder 31 running against stationary arcuate sealing surfaces 36 and 37 that join to the housing around separator cylinder 17 . As noted preferred outer surface for cylinder 31 is composed of continuous, dense brush bristles that entrap the fiber tufts against arcuate surface 36 and an adjustable streamer plate 38 which has an acute angle fiber delivery tip to uniformly “payout” the fiber tufts to the teeth of the faster moving surface of cleaning cylinder 12 . That is to say, streamer plate 38 converges to a tip or edge at the interstice of cylinders 31 and 12 with the converging sides being substantially tangent to the adjacent cylinders. Streamer plate is mounted such that it can be mechanically adjusted as is well known in the industry relative to the transfer cylinder 31 and the cleaning cylinder 12 , such that fiber tufts being carried past sealing surface 36 is exposed at the tip or edge of streamer plate 38 to the teeth 13 of cleaner cylinder 12 , such that the fibers may be removed from transfer cylinder 31 for processing by cleaning cylinder 12 . By way of example, streamer plate 38 may be adjusted by appropriate shims or by incorporating an adjustment slot and selectively tightened bolts to allow the plate to vary in inclination and projection.
[0020] It should also be noted that cylinder 31 may be in the form of an air wheel having a solid cylindrical core 41 and a plurality of angularly spaced radially extending flights 42 or brushes which resiliently engage walls 36 and 37 as shown in FIG. 3 . The flights 42 would be angularly spaced at distances less than the arc defined by wall 36 or 37 such that at least one flight 42 would be in sealing engagement with wall 36 and another in sealing engagement with wall 37 at all times, thereby preventing the flow of air past cylinder 31 . Flights 42 would be sufficiently resilient to carry the fiber tufts past wall 36 to where the fibers would be engaged by cleaning cylinder 12 . The flights 42 may be brushes, belts or other strip like material.
[0021] As will also appreciated, a rotating doffing cylinder or brush 24 can remove the cleaned tufts from the teeth 13 of cleaning cylinder 12 and deliver the cleaned fibers to duct 26 . FIG. 2 also shows a form of air flow doffing without a doffing cylinder often used with the more open cleaning cylinders. As may be seen the doffing airstream through inlet duct 41 and outlet duct 42 moves in conjunction with the rotating teeth or lugs of cylinder 12 such that fibers are readily entrained in the airflow. The present invention makes air doffing without a doffing cylinder usable with the proven advantages of the high speed separator taught in application Ser. No. 12/168,497.
[0022] While the forgoing specification describes only a few embodiments of the present invention, the invention is not so limited and is intended to encompass the full scope of the claims appended hereto.
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An apparatus for cleaning foreign matter from separated tufts of fiber uses a transfer cylinder intermediate a revolving open reel type structure mounted within a porous housing to separate a conveying air stream from tufts of fiber conveyed thereby and a toothed cleaning cylinder to separate air flow through said revolving reel from said cleaning cylinder such that air is not drawn through said cleaning cylinder into said porous housing.
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BACKGROUND OF THE INVENTION
This is a division of application Ser. No. 448,817 filed Mar. 7, 1974, now U.S. Pat. No. 3,936,899, which in turn was a division of application Ser. No. 275,173 filed July 26, 1972, now U.S. Pat. No. 3,822,754.
This invention relates generally to an automatic swimming pool cleaner and more particularly to a cleaner comprised of a car adapted to travel underwater along a random path on the surface of a pool vessel.
Many different types of apparatus are disclosed in the prior art for cleaning swimming pools. An example is U.S. Pat. No. 3,291,145 which discloses a cleaner employing a floating head carrying high pressure liquid dispensing hoses which sweep the pool vessel walls so as to put any dirt thereon in suspension where it can be filtered out by the pool's standard filtration system. As further examples, U.S. Pat. Nos. 2,923,954 and 3,108,298 disclose cleaners in which wheeled vehicles move underwater along the pool vessel surface to collect debris and sweep the walls.
Prior art underwater cleaners have thus far met with only limited success for several reasons. Initially, in order to develop adequate traction between the wheels and pool vessel surface, they have typically had to be very heavy and cumbersome. Moreover, those underwater cleaners which employ an electrical motor have proved to be somewhat inconvenient because of the potential shock hazard. That is, since it is normally recommended that the motor not be operated while there are swimmers in the pool, the cleaner cannot safely be left in the pool under the control of a time clock. As a consequence, the use of such cleaners has, for the most part, been restricted to commercial applications.
Further, it is characteristic of most prior art underwater cleaners to utilize relatively complex reversing and steering mechanisms in order to achieve adequate surface coverage. Such complex mechanisms are generally costly and relatively unreliable.
In view of the foregoing, it is an object of the present invention to provide an improved underwater swimming pool cleaner.
SUMMARY OF THE INVENTION
Briefly, the present invention is directed to a swimming pool cleaner including a car adapted to travel underwater along a random path on the pool vessel surface. The car is supported on power driven wheels which frictionally engage the vessel surface to drive it in a forward direction. In accordance with an important aspect of the invention, means are provided on the car for developing one or more water flows having a force component perpendicular to a plane tangential to the wheels for increasing traction between the wheels and vessel surface. The water flows can, in addition, produce a forwardly directed force component which aids in propulsion and facilitates the climbing or spinning off of a vertical surface when encountered.
In accordance with a further aspect of the invention, a car wheel geometry is employed which produces a sidewise force component when the car wheels engage a vertical surface to thus cause the car to spin off and free itself from the surface without necessitating a reversal of driving direction.
In accordance with a still further aspect of the invention, the car structure is configured so that its center of gravity is close to the bottom of its vertical dimension so as to produce a torque tending to maintain it correct side up when on the pool bottom.
In accordance with a still further aspect of the invention, one or more hoses are coupled to the car and whipped by water flow therethrough to sweep the vessel surface and put any dirt thereon in suspension.
In accordance with a still further aspect of the invention, means are provided on the car for producing a suction adjacent to the vessel surface for pulling debris into a collection basket or bag carried by the car.
In a preferred embodiment of the invention, the car is formed of a platform supported on three wheels which engage the pool vessel surface. Two of the wheels are driven through gearing by a turbine which in turn is powered by water flowing thereto through a supply hose. In order to achieve the aforementioned spinoff effect, the two driven wheels are mounted for rotation about parallel, but spaced, axes. As a consequence, the leading edges of the driven wheels lie on a line which is not perpendicular to their direction of travel thus enabling the car to spin off obstructions and steep surfaces. The third wheel is mounted for rotation on an axis which pivots in a plane parallel to the plane tangential to the wheels so that this third wheel may be differently oriented for different pool surface slopes, thereby helping to randomly steer the car. Alternatively, positive drive means such as a linkage to the turbine can be provided to gradually pivot the third wheel or vary the discharge angle of a water jet to assure random car movement.
The water flow producing a force component perpendicular to the vessel surface is preferably developed by diverting a low volume, high velocity water flow from the supply hose to an orifice to thus pull water into the lower end of a venturi having a directional component extending perpendicular to the car platform which water is then discharged at the venturi's upper end. The force reaction presses the wheels against the pool vessel surface to thus develop significantly greater traction for propulsion than the weight of the car alone could provide. As a consequence, the car can be constructed of relatively light and low cost materials and have the capability of climbing vertical surfaces. The suction produced adjacent the vessel surface by the water being pulled into the lower tube end draws debris from the pool surface into a collection basket carried by the car. Although a single water flow is used in the preferred embodiment of the invention for providing the primary hold down force as well as suction for picking up debris, it will be readily recognized that separate flows could be provided for this purpose if desired.
In accordance with another aspect of the invention, a portion of the water supply is diverted through the trailing sweep hoses to randomly whip them against the pool vessel surface.
In accordance with a still further aspect of the invention, means are provided within the collection basket for pulverizing leaves so that the remains can then be discharged and put in suspension in the pool water for later removal by the main filter system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric sectional view illustrating a pool cleaner in accordance with the present invention in a typical swimming pool;
FIG. 2 is a side elevation view of a preferred embodiment of the present invention;
FIG. 3 is a sectional view of a pool cleaner in accordance with the present invention taken substantially along the plane 3--3 of FIG. 2;
FIG. 4 is a side view, partially broken away, of a pool cleaner in accordance with the present invention;
FIG. 5 is a sectional view taken substantially along the plane 5--5 of FIG. 3.
FIG. 6 is a sectional view taken substantially along the plane 6--6 of FIG. 3;
FIG. 7 is a sectional view taken substantially along the plane 7--7 of FIG. 3;
FIG. 8 is a plan view partially broken away illustrating an alternative arrangement including a linkage coupling the turbine to the third wheel to cause random steering and a means for pulverizing leaves and other debris sucked into the collection basket;
FIG. 9 is a side elevation, partially broken away, of the pool cleaner of FIG. 8; and
FIG. 10 is a sectional view taken substantially along the plane 10--10 of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Attention is now called to FIG. 1 which illustrates a cutaway isometric view of a typical residential or commercial swimming pool. The water 10 is contained within a vessel 12 generally defined by a reinforced concrete wall 14 poured to conform to the shape of an excavated hole. Typically, a hole is excavated which defines a relatively deep end 16 and a relatively shallow end 18. In conforming to the shape of the excavation, the wall 14 generally defines substantially horizontal or floor portions 19 as well as substantially vertical or wall portions 20 which rise above the intended level of the water 10 to decking or coping 21.
Typically, filtration systems employed with swimming pools of the type illustrated in FIG. 1 include a main pump and filter 22 for taking water from the pool, filtering the water, and returning the filtered water to the pool. Such filtration systems employ water intake ports, such as a surface or skimmer intake 24 and a below water level drain intake 26. The filtration system sucks water into the intakes 24 and 26, and after filtration, returns the water to the pool via a return line 27 and return ports 28 extending through the vertical wall portion 20 close to the water line.
Although the typical swimming pool filtration system does quite an adequate job of filtering the water to remove fine debris particles suspended therein, such systems are not effective to remove debris, such as leaves, which settle on the floor of the pool or fine particles of debris which settle on both the floor and vertical wall portions of the pool vessel surface. As a consequence, in order to maintain a swimming pool clean, it is necessary to periodically sweep the wall surface, as with a longhandled brush, to place any fine debris in suspension. Additionally, it is also necessary to periodically vacuum the pool floor to remove larger debris such as leaves.
The present invention is directed to a cleaning apparatus 30 which travels along a random path on the surface of the pool vessel to both sweep the walls and suck debris into a debris container carried thereby.
Attention is now called to FIGS. 2-7 which illustrate a preferred embodiment of pool cleaner in accordance with the present invention.
The pool cleaner 30 is comprised of a car 32 having a frame or body structure 34 supported on some type of movable traction means such as wheels 36a, 36b, 36c. As shown in FIG. 4, the frame structure 34 can be essentially pan shaped, consisting of a bottom plate or platform 38 and upstanding sidewall 40 extending around the periphery thereof. A dome or cover member 41 is provided having depending sidewalls 42 which mate with upstanding sidewall 40.
In accordance with the present invention, a turbine mechanism 44 is mounted within the frame structure 34 for producing rotary motion in response to a pressured water/flow supplied thereto. The turbine 44 can be conventional in design having a water inlet port 46, a water outlet port 48, and a power output shaft 50 which is rotated in response to water being supplied to the port 46.
The output shaft 50 extends axially in both directions from the turbine 44 and is supported for rotation in openings through wall portions 51, 52. Small gears 54, 56 are secured to the shaft 50 at opposite ends thereof. The gear 54 is engaged with an annular rack 58 formed on the inner surface of wheel 36a as is best shown in FIGS. 3 and 4. The wheel 36a is mounted for rotation on axle 59 which extends parallel to, but is spaced from, shaft 50. The gear 56 is similarly engaged with annular rack 60 formed on the inner surface of wheel 36b mounted for rotation on axle 61. Axle 61 also extends parallel to shaft 50 but is spaced therefrom in the direction opposite from axle 59. In contrast to the drive or traction function performed by wheels 36a and 36b, wheel 36c is merely a support wheel, as shown in FIGS. 3 and 4 mounted for rotation about axle 71. Axle 71 can be mounted for pivotal movement about pin 72 to better enable the wheel 36c to follow the contour of the vessel surface.
The turbine 44 is powered by water supplied to the port 46 via conduit 62 coupled to outlet 64 of a water supply mainfold 66. A pressured water/flow is supplied to the inlet 68 of the manifold 66 through a supply hose 69 preferably from a booster pump 70 (FIG. 1). As the turbine 44 rotates to drive the shaft 50, both the wheel 36a and the wheel 36b will rotate.
It will be noted from FIG. 3 that although the wheels 36a and 36b rotate about parallel axes, the axes are offset with respect to one another. In other words, a line projected between the axes of wheels 36a and 36b will be skewed with respect to the planes of rotation of the wheels. As a consequence of this skew arrangement, the car will avoid getting stuck against vertical walls or barriers. That is, in its random travel along the pool vessel surface, even if the wheels 36a and 36b simultaneously engage a large obstacle such as the vertical wall of a step, the skewed relationship of the wheels 36a and 36b relative to the direction of travel will produce a force component extending parallel to the vertical wall to thus enable the car to spin off and thus avoid getting stuck in a position from which it cannot emerge.
It will be recalled from FIG. 1 that the wall 14 of a typical pool is shaped with a relatively large radius of curvature between the substantially horizontal or floor portions of the pool vessel and the substantially vertical or sidewall portions. In other words, for structural integrity and to facilitate water flow, many modern pools are not constructed with sharp corners between floor and wall. In order to most effectively clean a pool, it is desirable of course that the car be able to traverse as much of the pool vessel surface as possible. In other words, it is desirable that the car be able to climb the substantially vertically oriented portions of the pool vessel wall. In order to accomplish this, the car 32 in accordance with the present invention is provided with water powered means for producing a thrust to increase traction between the wheels 36 and the vessel surface. In accordance with the preferred embodiment of the invention, this thrust is produced by a water jet discharged from a directionally adjustable nozzle 90 and by a water stream discharged from a suction or vacuum unit 91. The two thrust components produce a substantial force extending normal to the vessel surface thereby increasing traction between the wheels 36a, 36b, 36c and the vessel surface and enabling the car to climb vertical surfaces. should be
The nozzle 90 is preferably mounted on some type of universal fitting such as a ball coupling 92 which couples the nozzle to the supply manifold 66 for receiving a high pressure water supply from booster pump 70. The angle of the nozzle 90 is selected to yield both a downward thrust component (i.e. normal to the vessel surface) for providing traction and a forward component which aids in propelling the car and facilitates the car climbing vertical surfaces and working itself out of corners. Set means (not shown) can be provided for holding the selected angle of the nozzle and valve means (not shown) can be provided for varying the flow rate through the nozzle 90.
In use, as the car is propelled along the vessel surface by rotation of the drive wheels 36a and 36b, the vacuum unit 91 will always discharge a water flow having a component normal to the portion of the vessel surface on which the car then rests. The intensity of the water flow is selected to produce a reaction force sufficient to enable the car to climb vertical surfaces. As the car climbs, the combined effects of gravity, the cars inherent flotation characteristics and the directional variations produced by the water jet (and other effects to be discussed) cause a change in direction of travel causing the car to fall off the vertical surface and reestablish its travel along another path. In order to assure that the car lands correct side up, the car is designed to have a relatively low center of gravity; i.e. the weight distribution of the car is selected so that its center of gravity is close to the bottom of its vertical dimension, so as to thereby produce a bouyant torque tending to maintain it correct side up. The entire car structure is preferably designed to weigh very little when underwater, thereby assuring that the hold down force produced by the water flow together with the weight distribution of the car, will cause the car to land correct side up whenever it falls from a wall surface.
The car carries with it one or more sweep hoses 96 which are trailed along and whip against the vessel surface. More particularly, a hose 96 is coupled to a tube 100 communicating with the interior of the supply manifold 66. The remote end of the hose 96 is left open via an orifice. Water flowing from the manifold 65 and tube 100 through the hose 96 will exit through the open hose end and in so doing will produce a reaction force on the hose whipping it in random directions. As a consequence, it will rub against and sweep fine debris from the vessel surface, putting it in suspension for removal by the pools standard filtration system. A float 102 is preferably mounted around the tube 100 to facilitate dynamic balance of the car. A valve 104 is preferably incorporated in the tube 100 for controlling the flow rate to the sweep hose and thus the whipping action thereof.
In the course of moving along a random path on the pool vessel surface in a manner thus far described, it is of course the function of the cleaner to clean the surface as by putting fine debris thereon in suspension for removal by the standard filtration system.
In addition, in accordance with the invention, large debris such as leaves are collected by the subject cleaner by the vacuum unit 91 which produces a suction close to the pool vessel surface. More particularly, a suction or vacuum head 110 (FIGS. 3 and 4) extending across substantially the full width of the car between the wheels 36a and 36b is defined in the plate 38. The suction head 110 defines a suction opening 112 at the bottom thereof. The opening 112 narrows down and communicates with the lower end 114 of a venturi tube 116. An orifice 118 is mounted in the throat of the venturi tube 116 for discharging a flow of water therethrough toward the open end 122 of the venturi tube. Orifice 118 receives water flow via conduit 124 coupled to outlet 126 on the supply manifold 66. As should be appreciated, the water discharged from the orifice 118 produces a reduced pressure in the throat area of the venturi tube thus producing a suction at the entrance opening 112. As a consequence, water and debris are drawn from the vessel surface into the opening 112 and through the venturi tube 116. The water and debris are then discharged through the open venturi end 122 into a debris collection container. In the embodiment of the invention illustrated in FIGS. 2-7, the debris collection container constitutes a bag 124 formed of mesh material having an entrance opening sealed around the open end 122 of the venturi tube 116 by a band 125. The bag 124 is of course removable from the venturi tube 116 for cleaning or disposal.
Reference was previously made to a supply hose 69 for supplying a pressured water flow to the manifold 66. In order to assure that the car does not get entangled with the supply hose 69, it is preferable that the hose float during operation as is represented in FIG. 1. The hose of course can be caused to float by mounting suitable floats thereon. More particularly, the supply hose 69 can comprise a one-half inch inner diameter plastic hose, for example, having a swivel coupling 164 mounted in a first end 160 thereof. The swivel coupling 164 is adapted to be threaded into an outlet 166 provided in the pool vessel surface adjacent to the water surface. A water booster pump 70 which can divert water out of the pool's standard filtration system, provides a high pressure flow to the outlet 166. The second end 162 of the hose 69 is coupled by a similar swivel coupling 170 to the previously mentioned supply manifold 66.
From the foregoing, it will be recognized that a swimming pool cleaner has been disclosed herein which is comprised of a car which travels along a random path on the surface of a pool vessel propelled by traction wheels powered by a water driven turbine. As a consequence of employing the previously discussed water streams to produce a significant traction force between the wheels and the vessel surface, the car can be constructed of light-weight inexpensive materials, such as plastic. By being able to utilize light weight materials such as plastic, a car in accordance with the invention can be produced quite inexpensively. Moreover, by designing the car so as to assure full coverage of the pool vessel surface without requiring complex steering and reversing mechanisms, cost reduction and reliability improvement is further enhanced. Although a particular embodiment of the invention has been illustrated in FIGS. 2-7, it should be readily apparent that many variations can be made without departing from the spirit or scope of the invention. Thus, for example only, an alternative arrangement is shown in FIGS. 8-10 wherein, in lieu of utilizing a separate debris collection bag, the car structure itself forms the debris container with the car cover member 200 being perforated to permit water flow therethrough.
Utilization of the arrangement of FIGS. 8-10 contemplates that a user remove the dome 200 and then clean the debris from the pan shaped frame structure. In both the arrangement of FIGS. 8-10 and the arrangement of FIGS. 2-7, the mesh size for the water permeable material should be selected to suit a particular set of conditions. For example, in pool situations where many leaves are encountered, it would be desirable to utilize, material with relatively large holes so as to contain most of the leaves and enable the water to freely flow therethrough to suspend the rest of the debris for removal by the filter system. On the other hand, a pool with few leaves but a heavy silt problem would preferably use a very closely woven container material to remove the silt and reduce the load on the filter system.
In using the subject pool cleaner, it has been recognized that as the leaves collect within the container, the high velocity water stream discharged from the upper end of the venturi tube continually beats the leaves against the container screen material. As a consequence, the leaves are pulverized into fine particles which pass through the screen material and go into suspension in the water from which they can be removed by the pools regular filtration system. As a result of this action, the frequency with which the debris must be removed from the container is considerably reduced. In pool situations with a greater then normal leaf problem a pulverizing means 210 (FIGS. 8 and 9) can be incorporated in the container to more positively pulverize the leaves. More particularly, as shown in FIG. 8 a collar 212 carrying a plurality of radially extending blades 214 can be mounted on turbine shaft 50'. As the shaft 50 rotates, the blades 214 move past fixed blade 216 shredding leaves therebetween.
In order for the pool cleaner to function effectively, it should travel in a highly random manner so as to substantially cover the entire vessel surface. Various factors operating on the car depicted in FIGS. 2-7 will tend to produce this random motion. Such factors include the vessel surface terrain, the action of the whip hose 96 and the direction of the nozzle 90. However, it is recognized that if necessary, for certain pool situations, means can be incorporated in the car for positively randomizing the car motion. For example, attention is called to FIGS. 8-10 which illustrates one such means for varying the plane of rotation of the wheel 36c as the car moves. In the embodiment of FIGS. 8-10, the axle 71' of the wheel 36c is pivoted around pin 72' by a link 220 coupled between the axle 71' and gear 224. The gear 224 is engaged with worm gear 226 secured to turbine shaft 50'. As shaft 50' rotates, gears 224 and 226 rotate around their axes thus moving the end 228 of link 220 in a small circle. This alternately pulls and pushes the free end of axle 71' thus pivoting it about pin 72'.
It should be recognized that other arrangements can also be employed for achieving the random motion produced by the embodiment of FIGS. 8-10. For example only, the direction of the nozzle 90 can be varied as the car moves, a movable rudder can be employed and/or the flow rate through the sweep hose can be varied.
From the foregoing, it will be recognized that an improved swimming pool cleaner has been disclosed herein which is capable of randomly traveling on the pool vessel surface and collecting debris therefrom as well as dislodging debris from the surface for collection by the pools standard filtration system. Although a preferred embodiment of the invention has been illustrated herein, it is recognized that numerous variations and modifications can be made therein without departing from the spirit and scope of the invention. Thus, for example only, tractions means other than the round wheels can be employed for increasing traction area or for facilitating travel of the car over low obstructions, such as a hose. Similarly, means can be provided for changing drive direction in special pool situations where the car could get stuck against some obstacle. It should also be recognized that although the preferred embodiments of the invention illustrated herein employ a booster pump 70 for optimum performance, the booster pump could be eliminated in a low cost system and the turbine could be driven by water flow from the main pump.
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An automatic swimming pool cleaner comprised of a car adapted to travel underwater along a random path on the pool vessel surface for dislodging debris therefrom. The car wheels are driven by a water powered turbine to propel the car in a forward direction, along the vessel surface. In order to prevent the car from being driven into a position, as for example against a vertical wall, from which it cannot emerge, a wheel geometry is employed which, upon contact, develops a horizontal force component parallel to the vertical wall, to thus enable the car to spin off. Alternatively, or in combination, a water flow produced reaction force can produce a torque to turn the car with respect to the engaged wheel to enable the car to spin off. The car is designed with a low center of gravity and a relatively buoyant top portion so as to produce a torque which maintains the car correct side up when on the pool bottom. Means are provided on the car for producing a water flow having a force component perpendicular to the vessel surface to provide good traction between the car wheels and the vessel surface. Further, a water flow produced suction is created adjacent to the vessel surface for collecting debris into a basket carried by the car. In addition, one or more hoses is pulled by the car and whipped by water flow to sweep dirt from the vessel surface for collecting debris into a basket carried by the car.
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BACKGROUND OF THE DISCLOSURE
The present invention relates to rotary fluid pressure devices, and more particularly, to such devices which include gerotor displacement mechanisms utilizing low-speed, commutating valving.
In a conventional gerotor motor utilizing low-speed, commutating valve (i.e., the rotary valve element rotates at the speed of rotation of the gerotor star rather than at the orbiting speed of the star) the valving action has been accomplished by means of a rotary valve member and a stationary valve member, with both valve members being separate from the gerotor displacement mechanism.
In recent years, those skilled in the art have developed what may be termed a "valve-in-star" (VIS) gerotor motor, an example of which is illustrated and described in U.S. Pat. No. 4,741,681, assigned to the assignee of the present invention and incorporated herein by reference. In a VIS motor, the commutating valving action is accomplished at an interface between the orbiting and rotating gerotor star, and an adjacent, stationary valve plate, which is typically part of the motor housing.
Although "commutating" valving action is well known to those skilled in the gerotor motor art, a brief explanation will be provided herein. In a typical gerotor motor, the ring member defines a plurality N+1 of internal teeth, and the orbiting and rotating star defines a plurality N of external teeth. The stationary valve member then defines a plurality N+1 valve passages communicating with the expanding and contracting fluid volume chambers of the gerotor, while the rotary valve member (orbiting and rotating star in the case of a VIS motor) defines a plurality N of fluid ports at high pressure ("system pressure"), and a plurality N of fluid ports at low pressure (return or exhaust). The progressive fluid communication between each of the N ports and each of the N+1 fluid passages, as the star orbits and rotates, comprises the commutating valving.
In a typical VIS motor, system pressure is communicated through the end cap, and the stationary valve surface, axially to a transverse face of the gerotor star, thus subjecting the star to a substantial axial separating force, tending to bias the star away from the stationary valve surface. Therefore, it has been necessary to provide a means to accomplish "overbalance" of the star, such that there is a net force tending to bias the star toward the stationary valve surface. This may be accomplished by providing the "backside" of the star (i.e., the side of the star opposite the end cap) with a pressure overbalance region, and then communicating system pressure into the region, from whichever set of star ports contains high pressure. Such an arrangement is illustrated and described in U.S. Pat. No. 4,976,594, assigned to the assignee of the present invention and incorporated herein by reference.
In commercial VIS motors produced by the assignee of the present invention (the Hydraulics Operations Worldwide of Eaton Corporation), communication of fluid to and from the star is accomplished by means of a pair of pressure chambers (or regions) defined by the end cap assembly. The first pressure chamber is annular, and the second pressure chamber is circular and is surrounded by the first pressure chamber. The above-described pressure chamber arrangement is illustrated and described in greater detail in both of the above-incorporated patents. Although the operating performance of the pressure chamber arrangement described above has been generally satisfactory, it has made pressure balancing of the star quite difficult. As will be understood by those skilled in the art of VIS motors, the annular, first pressure chamber has a larger area than the circular, second pressure chamber. As a result, when the second pressure chamber contains high pressure (for example, when the motor is operating counter-clockwise (CCW)), there is a much smaller hydraulic separating force acting on the star than when the first pressure chamber contains high pressure (when the motor is operating clockwise (CW)). Therefore, for a given pressure balance area on the backside of the star, there will be a much greater overbalance on the star when the motor is operating CCW than when the motor is operating CW.
As an example, during the development of the motor comprising the subject embodiment, using the pressure chamber arrangement described above, there was a 24% overbalance in the CCW direction, but a 0% "overbalance" in the CW direction. Those skilled in the art will recognize that a 0% overbalance is, in reality, no overbalance at all, and there is a great potential for axial separation of the star from the stationary valve plate, followed by cross-port leakage and stalling of the motor.
A seemingly obvious solution to the above problem would be to reduce the area of the annular, first pressure chamber, i.e., reduce the radial dimension of the first pressure chamber. However, reducing the area of the first pressure chamber, which must communicate with ports defined by an orbiting and rotating star, would typically reduce the area of communication therebetween enough to increase the pressure differential (pressure drop) across the motor to an undesirably high level.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved VIS motor design which provides for improved axial pressure balancing of the star, and more specifically, makes it possible to achieve a reasonable pressure overbalance for either direction of motor operation.
It is a more specific object of the present invention to provide an improved valving arrangement for a VIS motor in which the area of overlap of the annular, first pressure chamber and the adjacent star ports more nearly approximates the area of overlap of the star fluid ports and the stationary valve passages.
It is a further object of the present invention to provide an improved VIS motor which accomplishes the above-stated objects without restricting fluid flow from the annular, first pressure chamber to the star ports to such an extent that the pressure differential across the motor becomes excessive.
The above and other objects of the invention are accomplished by the provision of an improved rotary fluid pressure device of the type comprising housing means including an end cap member defining a fluid inlet port and a fluid outlet port. A gerotor gear set is associated with the housing means and includes an internally-toothed ring member defining a plurality N+1 of internal teeth, and an externally-toothed star member defining a plurality N of external teeth, the star member being eccentrically disposed within the ring member for orbital and rotational movement relative thereto. The teeth of the ring member and the star member interengage to define a plurality N+1 of expanding and contracting fluid volume chambers during the relative orbital and rotational movements. The end cap member includes stationary valve means including a first fluid pressure region in continuous fluid communication with the inlet port, and a second fluid pressure region in continuous fluid communication with the outlet port, the first region surrounding the second region. The stationary valve means further defines a plurality N+1 of valve passages, each being in continuous fluid communication with one of the fluid volume chambers. The star member defines a manifold zone in continuous fluid communication with the second fluid pressure region, the star member including an end surface disposed in sliding, sealing engagement with an adjacent surface of the stationary valve means. The end surface of the star member defines a first plurality N of fluid ports and a second plurality N of fluid ports, the second plurality of fluid ports being in continuous fluid communication with the manifold zone.
The improved rotary fluid pressure device is characterized by each of the first plurality N of fluid ports including inward portions extending radially inwardly beyond each of the second plurality N of fluid ports. The first fluid pressure region comprises a plurality N+1 of individual stationary ports defined by the adjacent surface of the stationary valve means. Each of the N+1 stationary ports is in commutating fluid communication with each of the inward portions of the first plurality N of fluid ports defined by the star member during the relative orbital and rotational movements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial cross-section illustrating a low-speed, high-torque VIS gerotor motor made in accordance with the present invention.
FIG. 2 is a transverse cross-section, taken on line 2--2 of FIG. 1, but illustrating only the gerotor star, and on a scale larger than FIG. 1.
FIG. 3 is a transverse cross-section, taken on line 3--3 of FIG. 1, and on a scale larger than that of FIG. 1 but smaller than that of FIG. 2.
FIGS. 4-7 are fragmentary, overlay views illustrating the operation of the present invention in four different orbital and rotational positions of the star.
FIG. 8 is a graph of overall efficiency (as a percentage) versus system pressure (in PSI) comparing the present invention with the prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, which are not intended to limit the invention, FIG. 1 illustrates a VIS motor made in accordance with the above-incorporated patents. More specifically, the VIS motor shown in FIG. 1 is, by way of example only, of a "modular" design, made in accordance with the teachings of U.S. Pat. No. 5,211,551, assigned to the assignee of the present invention and incorporated herein by reference.
The VIS motor shown in FIG. 1 comprises a plurality of sections secured together such as by a plurality of bolts 11, only one of which is shown in each of FIGS. 1 and 3. The motor includes an end cap 13, a stationary valve plate 15, a gerotor gear set, generally designated 17, a balance plate 19, and a flange member 21.
The gerotor gear set 17 is well known in the art, is shown and described in greater detail in the above-incorporated patents, and therefore will be described only briefly herein. The gear set 17 is preferably a Geroler® gear set comprising an internally toothed ring member 23 defining a plurality of generally semi-cylindrical openings, with a cylindrical roller member 25 disposed in each of the openings, and serving as the internal teeth of the ring member 23. Eccentrically disposed within the ring member 23 is an externally-toothed star member 27, typically having one less external tooth than the number of internal teeth 25, thus permitting the star member 27 to orbit and rotate relative to the ring member 23. The orbital and rotational movement of the star 27 within the ring 23 defines a plurality of expanding and contracting fluid volume chambers 29.
Referring still primarily to FIG. 1, the star 27 defines a plurality of straight, internal splines which are in engagement with a set of external, crowned splines 31, formed on one end of a main drive shaft 33. Disposed at the opposite end of the shaft 33 is another set of external, crowned splines 35, adapted to be in engagement with another set of straight internal splines defined by some form of rotary output member, such as a shaft or wheel hub (not shown). As is well known to those skilled in the art, gerotor motors of the general type shown herein may include an additional rotary output shall supported by suitable bearings. For purposes of the subsequent description, and the appended claims, the main drive shaft 33 may be considered a form of output shaft, and the splines 31 and 35 may be considered the means which transmit torque to the output shaft.
Referring now primarily to FIG. 2, in conjunction with FIG. 1, the star member 27 will be described in greater detail. Although not an essential feature of the present invention, it is preferable that the star 27 comprise an assembly of two separate parts. In the subject embodiment, the star 27 comprises two separate parts including a main star portion 37, which includes the external teeth, and an insert or plug 39. The main portion 37 and the insert 39 cooperate to define the various fluid zones, passages, and ports which will be described subsequently.
The star member 27 defines a central manifold zone 41, defined by an end surface 43 of the star 27, the end surface 43 being disposed in sliding, sealing engagement with an adjacent surface 45 (see FIG. 3) of the stationary valve plate 15.
The end surface 43 of the star 27 defines a set of fluid ports 47, each of which is in continuous fluid communication with the manifold zone 41 by means of a fluid passage 49, defined by the insert 39 (only one of the fluid passages 49 being shown in FIG. 2). The end surface 43 further defines a set of fluid ports 51, which are arranged alternately with the fluid ports 47, each of the fluid ports 51 including a portion 53 which is defined by the insert 39 and extends radially inward, about half way, radially, to the manifold zone 41.
Referring now primarily to FIG. 3, in conjunction with FIG. 1, the end cap 13 and stationary valve plate 15 will be described in further detail. As may be seen from a review of the above-incorporated patents, it is known in the art to have the endcap and stationary valve plate formed as separate members, as in the subject embodiment, which then may also be referred to as an "endcap assembly". Alternatively, the endcap and stationary valve may comprise a single, integral part, in which case, reference to a "stationary valve means" or some similar terminology will be understood to refer to the portion of the endcap disposed immediately adjacent the gerotor gear set.
The endcap 13 includes a fluid inlet port 55 and a fluid outlet port 57. The endcap 13 defines an annular chamber 59 which is in open, continuous fluid communication with the inlet port 55. The endcap 13 and the stationary valve plate 15 cooperate to define a cylindrical chamber 61 which is in continuous, open fluid communication with the outlet port 57, and with the manifold zone 41, as the star 27 orbits and rotates.
Referring still primarily to FIG. 3, as was noted in the BACKGROUND OF THE DISCLOSURE, in the prior an VIS motors, the chamber 61 would have been surrounded by an annular pressure chamber having an effective area under pressure much larger than that of the chamber 61. However, in accordance with one aspect of the present invention, the annular pressure chamber of the prior art comprises a fluid pressure region, generally designated 63, which includes a plurality of individual stationary pressure ports 65, each of which is in continuous fluid communication with the annular chamber 59 by means of a passage 67 (see FIG. 1). It should be apparent to those skilled in the art that the total area under pressure of the ports 65 is substantially less than would be the area of an equivalent annular pressure chamber of the prior art. Therefore, the total separating force as a result of high pressure in the ports 65 will be substantially less than would be the case with the prior to art annular chamber.
The stationary valve plate 15 further defines a plurality of stationary valve passages 69, also referred to in the art as "timing slots". In the subject embodiment, each of the valve passages 69 would typically comprise a radially-oriented slot, each of which would be disposed in continuous, open fluid communication with an adjacent one of the volume chambers 29. Preferably, the valve passages 69 are disposed in a generally annular pattern which is concentric relative to the fluid pressure region 63, as is illustrated in FIG. 3. In the subject embodiment, and by way of example only, the valve passages 69 each open into an enlarged portion 71. Each of the bolts 11 passes through one of the enlarged portions 71, but as may be seen in FIG. 3, and in FIGS. 4 through 7, even with the bolt 11 present, fluid can still be communicated to and from the volume chambers 29 through the radially inner part of each enlarged portion 71.
Referring again primarily to FIG. 1, the plate 19 functions as a "balancing plate", in accordance with the teachings of above-incorporated U.S. Pat. No. 4,976,594. System pressure (high pressure) is communicated to the backside (side adjacent the flange member 21 ) of the plate 19. For either direction of operation, the radially inward portion of the plate 19 is biased toward the star member 27. In other words, throughout one entire orbit of the star member 27, there is a net force biasing the plate 19 toward the star. However, for various reasons such as a slight tipping or cocking of the star, there may be localized areas in which there is a slight separation of the balancing plate 19 from the star 27.
During operation, high pressure fluid is communicated to the inlet port 55, and from there flows to the annular chamber 59, then through the individual passages 67 and into the pressure ports 65. As the star 27 orbits and rotates, the nine pressure ports 65 engage in commutating fluid communication with the eight radially inward portions 53 of the fluid ports 51 defined by the star 27. Thus, high pressure fluid is being communicated only to those fluid ports 51 which are in fluid communication with one of the valve passages 69, or are about to have such communication or have just completed such communication, as will be described subsequently in connection with FIGS. 4 through 7.
High pressure fluid is communicated only to those fluid ports 51 which are on the same side of the line of eccentricity as the expanding volume chambers, so that high pressure fluid then flows from those particular fluid ports 51 through the respective stationary valve passages 69, and enlarged portions 71, into the expanding volume chambers 29.
Low pressure exhaust fluid flowing out of the contracting volume chambers 29 is communicated through the respective enlarged portions 71 and valve passages 69 into the fluid ports 47 defined by the star member 27. This low pressure fluid is then communicated through the radial fluid passages 49 into the manifold zone 41, and from there, the low pressure fluid flows through the cylindrical chambers 61, and then to the outlet port 57. It will be understood by those skilled in the art that the overall flow path just described is generally well known in the art.
Referring now primarily to FIGS. 4-7, one important aspect of the present invention will be described. It should be noted that in FIGS. 4-7, the view is toward the valve plate 15, in the same manner as in FIG. 3, but the elements of the star 27 appear "reversed" from the view in FIG. 2 because, in FIGS. 4-7, the element of the star 27 are being viewed in a direction opposite that of FIG. 2.
Referring now primarily to FIG. 4, when a particular external tooth of the star 27 is in a "bottom dead center" position, as shown in FIG. 4, the pressurized fluid port 51 is just approaching a line-to-line communication with the stationary valve passage 69. However, even before communication between the port 51 and the passage 69, pressurized fluid is communicated through the area of overlap (shaded area) between the pressure port 65 and the inward portion 53 of the fluid port 51, in preparation for communication from the port 51 to the passage 69, thus assuring that there will not be any cavitation when communication from the port 51 to the passage 69 first occurs.
Referring now primarily to FIG. 5, after 45 degrees of orbital movement of the star 27, the area of overlap (shaded area) between the pressure port 65 and the inward portion 53 has increased somewhat. At the same time, the area of overlap (shaded area) of the fluid port 51 and the passage 69 has also increased substantially such that the second area of overlap is approaching, and is approximately equal to, the first area of overlap. For simplicity of illustration and explanation, it will be assumed that the areas of overlap shown in FIGS. 4 through 7 are representative of the actual flow areas between the particular ports and passages involved.
Referring now primarily to FIG. 6, by the time the star 27 has reached about 90 degrees of orbital movement, the first area of overlap between the pressure port 65 and the inward portion 53 has increased even further, reaching approximately its maximum flow area. At the same time, the second area of overlap, between the fluid port 51 and the passage 69 has increased to its maximum flow area, with the first and second areas of overlap (flow areas) being very nearly equal.
As the star member 27 continues to orbit, past the 90 degree position shown in FIG. 6, each of the areas of overlap begins to decrease, with the second area of overlap, between the fluid port 51 and the passage 69, decreasing somewhat more rapidly. Finally, the position shown in FIG. 7 is reached when the star has orbited 180 degrees, and the fluid port 51 has just passed out of line-to-line contact with the passage 69. In other words, the second area of overlap has become zero. At the same time, the first area of overlap, between the pressure port 65 and the inward portion 53, has decreased to the very small area of overlap shown in FIG. 7.
FIGS. 4-7 illustrate an important aspect of the present invention whereby the first and second areas of overlap are "approximately equal" during the one-half of each orbit during which high pressure is being communicated to expanding volume chambers. By "approximately equal" it is meant that the two areas of overlap are of the same general order of magnitude, and that they are both increasing at the same time (from zero degrees to 90 degrees) and then are both decreasing at the same time (from 90 degrees to 180 degrees). As a practical matter, and for reasons which will be understood by those skilled in the art, the first area of overlap is larger than the second area of overlap near the beginning of the orbital cycle and toward the end of the orbital cycle. However, the first and second areas of overlap will be considered "approximately equal", as that term is used hereinafter and in the appended claims, as long as the areas of overlap have the type of relationship illustrated in FIGS. 4-7.
Referring now primarily to FIG. 8, which is a graph of overall efficiency.(the product of mechanical efficiency and volumetric efficiency), as a function of system pressure. The two curves marked "PRIOR ART" represent a motor such as is shown in FIG. 1, but including a prior art annular groove in place of the fluid pressure region 63.
The two upper curves (marked "INVENTION") represent the performance of a motor made in accordance with the present invention, utilizing the pressure ports 65. In summary, at 5000 psi system pressure, and 10 gpm system flow, the prior art motor, operating clockwise, had an overall efficiency of about 47%, while the motor of the present invention had an overall efficiency of about 62%. More importantly, the prior art motor, operating in the counter-clockwise direction, had dropped to an overall efficiency of about 10%, while the motor of the present invention, operating in the counter-clockwise direction, still had the same overall efficiency of about 62%.
The invention has been described in great detail in the foregoing specification, and it is believed that various alterations and modifications of the invention will become apparent to those skilled in the art from a reading and understanding of the specification. It is intended that all such alterations and modifications are included in the invention, insofar as they come within the scope of the appended claims.
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A gerotor motor of the valve-in-star type in which the star (27) is disposed adjacent a stationary valve plate (15). The stationary valve plate (15) defines a plurality N+1 of stationary ports (65) in communication with the inlet port (55). The gerotor star (27) defines a plurality N of fluid ports (51) each including a radially inner portion (53). The inner portions (53) and the stationary port (65) are in commutating fluid communication as the star (27) orbits and rotates, in accordance with an important aspect of the invention. As a result, the star member (27) is exposed to a smaller area of pressurized fluid at the stationary valve plate (15), thus making it possible to achieve more consistent overbalance of the star, for either direction of rotation. This results in substantially improved overall efficiency of the motor.
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FIELD OF THE INVENTION
The present invention relates to shower heads and particularly to shower heads which have more than one type of shower spray.
BACKGROUND OF THE INVENTION
Some shower heads have a single spray plate in which there are a series of apertures. When the water supply in turned on, water is delivered to the spray plate is a steady, continuous stream. This is a single mode shower head and the type of spray is referred to herein as a regular spray.
Shower heads with more than one mode are known. Such modes include a regular spray and pulsed spray. The user selects the mode required by moving one part of the shower head relative to the rest of the shower head. One example of such a shower head is disclosed in U.S. Pat. No. 4,754,928. The shower head disclosed in this specification has four spray modes which includes a variable pulsating misting spray. The user selects the type of spray by rotating the bottom section of the shower head.
The misting effect in U.S. Pat. No. 4,754,928 is achieved by using a water path which expands in diameter during its passage through the shower head. The increase in diameter causes the liquid to atomise and so produces a mist. Similarly, U.S. Pat. No. 4,657,185 discloses a mist spray caused by a pressure drop due to a divergent frustoconical shape in the walls of the spray nozzle.
One effect of a mist spray is the creation of steam and so, in effect, produce a sauna in the shower stall. The effect is enhanced by using very hot water. The user then runs the risk of scalding himself/herself by selecting a different shower mode immediately after using the mist spray with very hot water.
U.S. Pat. No. 4,084,271 describes a shower attachment which enables a user to produce a sauna within a shower cubicle. The device in that patent produces steam by directing the hot water through a dedicated hose attached to the water supply behind the shower head and spraying it through a nozzle against the wall of the shower cubicle. The water supply is diverted from the normal shower head to the steam nozzle and back again by the user operating a dual ended plunger. Although, the specification refers to the possibility of scalding, it is merely in relation to the effect of the steam.
GB 2,066,704 discloses a device which produces steam through an aperture in the side of the shower head by directing hot water at a deflector shaped so that it atomises the liquid and sprays the droplets into the shower cubicle. A user switches between mist mode and other shower modes by sliding part of the shower head with respect to the water input. The design of the mist producing element is such that in order for the user to return to one of the other shower modes he must overcome the pressure of water acting on the deflector. Although, the patent discloses that the force of water makes such adjustment "extremely difficult", such adjustment is not completely impossible. Further, in the device disclosed in this patent, the mist producing part is fixed to the wall, even if used in connection with a shower head which is detachable.
SUMMARY OF THE INVENTION
Accordingly, it is the intention of the present invention to provide a shower head having more than one spray mode in which the mist spray is delivered through the same face of the shower head as the other spray modes and which incorporates a locking device which prevents the user from selecting a different shower mode after using the mist spray and so risk scalding him or herself with very hot water.
According to the present invention, there is provided a shower head having more than one spray mode including a mist spray mode, the shower head comprising a portion including a water inlet, means moveable relative to the inlet portion to bring selectively into register with the inlet a plurality of spray faces each capable of providing a different spray mode, and one of which is a spray face producing the mist spray, and a locking device operable to prevent movement of the mist-producing spray face relative to the inlet portion when the mist spray mode has been selected.
Suitably, the locking device is moveable into a locking position to prevent such movement by means of pressure of water within the shower head and is preferably releasable to allow the said movement when the pressure of water within the shower head is below a threshold value. It is preferred that the locking device is only operable in connection with the mist spray mode.
In a preferred embodiment, the locking device comprises a locking pin moveable between an open position in which the locking pin allows the said movement of the mist-producing spray face and a locking position in which the locking pin prevents the said movement of the mist-producing spray face. Suitably, the locking pin is biassed towards the open position. Preferably, the locking pin is located within the inlet portion and the means moveable relative to the inlet portion includes a restraint with which the locking pin is engageable in the mist spray mode to prevent such movement.
The mist spray mode suitably comprises mist channels leading to mist apertures and a spiralling water path in each channel whereby water will emerge from the mist apertures as a fine spray or mist. In a preferred form, each mist channel contains a mist pin which at least partly provides the spiralling water path. The water path may be provided by spiralling grooves in the surface of each mist pin or alternatively by a twisted water channel through each mist pin. In an alternative form, the water path may be provided between spiralling grooves in the walls of each mist channel and the mist pin is in the form of a stopper located in each mist channel adjacent the grooves.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described, by way of illustration only, and with reference to the drawings, wherein:
FIG. 1 shows a side view of a shower head according to one embodiment of the present invention;
FIG. 2 shows a view along II--II in FIG. 1;
FIG. 3 shows a view of the inside of the outer body;
FIG. 4 shows an exploded side view of part of the shower head;
FIG. 5a shows the inner body from above;
FIG. 5b shows a cross-section of the inner body;
FIG. 5c shows the inner body from below;
FIG. 6a shows the divider from above;
FIG. 6b shows a cross-section of the divider;
FIG. 6c shows the divider from below;
FIG. 7a shows the diverter from above;
FIG. 7b shows a cross-section of the diverter;
FIG. 7c shows the diverter from below;
FIG. 8 shows a cross-section of the shower head along VIII--VIII in FIG. 2;
FIG. 9 shows a mist pin;
FIG. 10 shows an exploded cross-section of the spray plates;
FIG. 11a shows the spray plate from below;
FIG. 11b shows the spray plate from above;
FIG. 12a shows the impeller from below;
FIG. 12b shows the impeller from above;
FIG. 13a shows the pulse plate from below;
FIG. 13b shows the pulse plate from above;
FIG. 14 shows the mini spray plate from below;
FIGS. 15 to 18 show cross-sectional views with the water path for each spray mode illustrated;
FIG. 19 shows a divider according to a second embodiment of present invention from above;
FIG. 20 shows a view along XX--XX in FIG. 19; and
FIG. 21 shows an enlarged view of the water path through the mist channel, along XXI--XXI in FIG. 19.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As shown in FIG. 1, the shower head 10 comprises a handle 12, an outer body 14 and a multi-spray head 16. The multi-spray head is surrounded by a grip ring 18.
FIG. 2 shows the shower face 20 of the multi-spray head. There are four sets of apertures in the shower face 20 which are arranged concentrically. Only one set of apertures at a time can be connected to the water supply and each provides a different type of water spray. The apertures 22 in the central area provide a limited water flow, known as regulated water saver. The first ring of apertures 24 are arranged in 3 groups.
Water is delivered to each of these groups of apertures in turn to produce a pulsed spray. The apertures 26 in the second ring are spaced equally and produce a regular spray. From the apertures 28 in the outer ring water emerges as a fine spray or in the form of a mist.
FIG. 3 shows the interior of the outer body. The interior of the outer body has a skirt 30 dividing the interior into two parts. The handle 12 is hollow. The interior of the handle 12 is connected to the interior of the outer body 14 by an aperture 32 at the base of the skirt 30. Part of the inner surface of the outer body has grooved mouldings 36. These are arranged so that the multi-spray head 16 can be screw threadedly attached to the outer body 14.
The multi-spray head will now be described with reference to FIGS. 4 to 8. The multi-spray head 16 comprises an inner body 38, a divider 40 and a diverter 42. The inner body 38 has a screw-thread 39 on the outer surface of its outer rim 41 and is designed to engage with the grooved mouldings 36 on the inside of the outer body 14. A flat washer 44 is located in a circular groove 46 on the top of the inner body 38. The skirt 30 in the outer body 14 engages the groove 46 and the join is sealed by the washer 44.
There is a channel 48 through the inner body 38 for water to pass from the interior of the outer body 14 to the divider 40. Water flow is restricted to the channel by a seal comprising a gasket 50 and a spring 52 (shown in FIG. 8). The spring 52 holds the gasket 50 against surface of the divider 40. The inner body 38 also has a nut 54 centrally located so that the divider 40 and the diverter 42 can be attached to the inner body 38 by a screw 56.
The inner body 38 also has a bore 58 in which a safety pin assembly 60 (shown in FIG. 8) is located. The safety pin assembly 60 comprises a spring 62, a gasket 64, a safety pin 66 and a pin cover 68. The pin cover 68 holds the 10 safety pin 66 in the bore 58 with the spring 62 partly compressed. The pin cover 68 has apertures 70, through which water can pass into the bore 58. The function of the safety pin assembly 60 is discussed below. The gasket 64 seals the bore 58 and prevents water leakage.
The divider 40 and the diverter 42 form a single unit in the shower head assembly. Four separate channels run through the divider-diverter unit, each leading to one of the four sets of apertures 22, 24, 26, 28 in the shower face 20. The divider-diverter unit is rotatable with respect to the inner body so that each of these channels may in turn be connected to the channel 48 in the inner body 38. The gasket 50 serves to restrain water from leaking into any channel in the divider-diverter unit other than the one with which the channel 48 is aligned.
The divider 40 comprises a central disk 71. It has a central aperture 72 into which the nut 54 fits when the divider 40 is aligned with the inner body 38. There are four other apertures 74, 76, 78 and 80 in the central disk 71, each of which leads into one of the four channels running through the divider-diverter unit. The divider has an outer rim 84 with two flanges 82. Each flange 82 has a small protrusion 86 which engages in shallow depressions 88 on the internal surface of the outer rim 41 of the inner body 38. These depressions 88 are spaced such that the two protrusions 86 engage in a pair of depressions 88 when one of apertures 74, 76, 78, 80 is aligned with the channel 48. The inner body 38 has an inner skirt 90 which has two stops 92. The divider 40 has a ring 96 above the central disk 71 which has a stop 98. The rotation of the divider 40 relative to the inner body 38 is thus restricted by the stop 98 abutting against stops 92 and 94 respectively. The grip ring 18 aids the user in rotating the divider-diverter unit when changing spray mode.
A V-Seal 100 between the divider 40 and the inner body 38 restrains water leakage.
The diverter 42 has a central aperture 110 for the screw 56. The diverter 42 has a moulding 102 on its upper surface 104 which engages the rim 106 on the lower surface 108 of the divider 40. The moulding 102 forms part of the four channels which direct water from the channel 48 to the different spray outlets. Water is directed from aperture 76 in the divider 40 to the water saver apertures 22 through a channel 136 in the moulding 102. Water is directed from aperture 78 in the divider 40 to the pulse mode apertures 24 through a channel 138 in the moulding 102. Water is directed from aperture through a channel 140 in the moulding 102, to the regular spray apertures 26. Water from aperture 80 is directed along a channel 142 in the moulding to the mist apertures 28. The divider 40 and diverter 42 are placed together by aligning the rim 106 on the lower surface 108 of the divider 40 with the moulding 102 on the upper surface 104 of the diverter 42. Each aperture in the divider 40 is then aligned with the correct channel in the moulding 102.
Around the rim of the diverter 42 are channels 112 leading to the mist apertures 28. Each channel 112 contains a mist pin 114, shown in FIGS. 8 and 9. Each mist pin 114 has a pair of spiralling grooves 115 which twist the stream of water travelling through channels 112 and so cause it to be emitted from the mist apertures 26 as a fine mist.
Once the mist pins 114 have been placed in the channels 112, the divider 40 and the diverter 42 are fitted together. They may then be welded or heat sealed to form a single unit.
The underside 116 of the diverter 42 comprises a series of concentric mouldings to which spray plates, shown in FIGS. 10 to 14, are attached. Spray plate 118 comprises the regular spray apertures 26. It snap fits with the mouldings on the underside 116 of the diverter 42. It has a seating 120 for an impeller 122 which is the functional part of the pulse spray mode. The spray plate 118 has an inner skirt 126 with four slots 124 cut at an angle to the circumference. The impeller 122 comprises a series of equispaced radial projections 128 and a flange 130 covering one-third of its surface. Water directed to the pulse spray mode goes through the slot 124 and, because of the angle, impacts on the radial projections 128 of the impeller and causes it to rotate.
Pulse plate 132 comprises the groups of pulse apertures 24. It is attached to the diverter 42 by a screw thread 136. The flange 130 of the impeller 122 covers approximately one-third of the pulse apertures 24 at any one time as the impeller 122 rotates. This blocks the water supply to one-third of the apertures in succession and so results in a pulsed water supply. The mini-spray plate 134, comprising the regulated water saver apertures 22, snap fits into the centre of the pulse plate 132.
FIG. 15 shows the shower head with the divider-diverter unit rotated to the regulated water saver spray. The line w--w illustrates the water path.
FIG. 16 shows the shower head with the divider-diverter unit rotated to the pulse spray mode. The line x--x illustrates the water path.
FIG. 17 shows the shower head with the divider-diverter unit rotated to the regular spray mode. The line y--y illustrates the water path.
FIG. 18 shows the shower head with the divider-diverter unit rotated to the mist spray mode. The line z--z illustrates the water path.
The mist spray is most effective when used with hotter water than is usual for showering. The effect of the grooves 115 in the mist pins 114 together with the small diameter mist apertures 28 when such hot water passes down the mist channels is to create steam, which can be used for saunas, facial cleansing etc. Because of this use of hotter water there is a risk that a user, returning the shower head from the mist spray mode to one of the other spray modes, could scald him/herself. The safety pin assembly 60 prevents such an occurrence. The spring 62 in the safety pin assembly 60 usually biasses the safety pin, 66 away from the divider 40. However, when the water pressure exceeds 10 psi, its force is greater than that exerted by the spring 62. The pressure of water on the surface of the gasket 64 will cause it to push the safety pin 66 towards the divider 40, so compressing the spring 62 further. Usually the safety pin 66 will rest against the central disk 71 of the divider 40. However, when the shower head is rotated to the mist spray mode the safety pin 66 is bought into alignment with the aperture 74 in the central disk 71. The water pressure acting on the surface of the gasket 64 will cause the safety pin 66 to move into this aperture and so lock the shower head in the mist spray mode. In order to release the safety pin 66, the user must reduce the water pressure to below 10 psi so that the spring 62 will expand and push safety pin 66 back into the bore 58. The shower head can then be rotated to a different spray mode.
A mist or fine spray can be produced by a number of specific embodiments, some of which are known from the prior art. The essential features of the mist spray disclosed in this specification are a twisted water path and a small mist aperture. Two further ways of implementing this aspect of the present invention are now described.
FIGS. 19 to 21 illustrate a second specific embodiment for creating a mist spray. The diverter 200 has a moulding 202 on its upper surface 204. As, with the first embodiment described above, the moulding has a series of channels which connect the apertures in the divider with the spray apertures. Each mist channel 206 contains a mist-pin 208. Each mist pin 208 has a water channel 210 which passes through it. The water channel 210 is not straight but is offset and so provides a twisted water path. The restriction on the water flow together with the twist in the water channel 210 causes water flowing through the mist channel 206 to spin. Water then emerges through the mist apertures 212 as a mist or fine spray. The line z'--z' illustrates the water path through the mist pin 208.
In a further embodiment (not illustrated), spiralling grooves are moulded into part of the walls of each mist channel, about two-thirds of the way down each channel. A stopper, such as a small rubber plug, is inserted into each mist channel and positioned adjacent the spiralling grooves so that water running through the mist channels is restricted to the grooves and so spins before reaching the mist apertures.
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A multi-spray shower head comprising a mist spray. When used with hot water this fine spray becomes steam. To prevent the user from scalding him- or herself immediately after using the mist spray with such hot water, the shower head includes a water operated safety pin assembly (60) which locks the shower head on the mist spray mode until the water pressure is reduced below a predetermined level. The mist spray is formed by passing water through mist channels (112) which have mist pins (114) which form spiralling water paths whereby water emerges from small diameter mist apertures (28) as a fine spray.
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TECHNICAL FIELD
[0001] The present invention relates to a molecular mimic mucosal AIDS vaccine for mucosal immunity.
BACKGROUND ART
[0002] The vaccine started with the smallpox shot by Edward Jenner in 1796 and after its conceptualization by Louis Pasteur, the vaccine has become an essential tool for biological defense. Although the molecular mechanism of biological defense by vaccination has been partly unraveled, much remains yet to be known. There is some misunderstanding about side reactions of vaccines and, in the past, inappropriate ways of their administration (such as needle sharing) have caused the problem of increased incidence of new infections (such as type C hepatitis.). HIV/AIDS vaccines have been mostly developed under the initiative of the United States of America but to date no substantial success has been gained.
[0003] Patent Document 1 discloses an intestinal immunity activator which comprises a compound represented by formula 1: TGDK-CH 2 —CH 2 —NH—R (wherein TGDK-CH 2 —CH 2 —NH-represents 2-[N-α, N-ε-bis(N-α, N-ε-digalloyllysinyl)lylsinyl]aminoethylamino group; R represents a moiety selected from the group consisting of a hydrogen atom, a group having an active ester group via a peptide bond, a group binding to a SH group via a peptide bond, a peptide, a protein, a lipid or a sugar that are bound via a peptide bond, or a peptide, a protein, a lipid or a sugar that are bound via a Schiff base). Patent Document 1 further discloses that the above-defined TGDK recognizes M cells.
CITATION LIST
Patent Literature
[0004] Patent Document 1: International Publication WO 2007/052641 A1 (International Application Number PCT/JP 2006/321720)
SUMMARY OF INVENTION
Technical Problem
[0005] The problem to be solved by the present invention is to provide an AIDS vaccine that is capable of inducing mucosal immunity, defending against breakdown of the immune system due to HIV infection, preventing HIV from escaping the immune system on account of its high mutability, and preventing rapid infection of HIV.
Solution to Problem
[0006] To solve the above-described problem, the present inventors made intensive studies focusing on a human protein structurally homologous to HIV Env gp120 envelope glycoprotein and commercially available under the trade name Fetuin (product of Sigma). Presumably, HIV may change the structure of gp 120 envelope protein into that of Fetuin (a molecular mimicry protein) to escape the barrier of the human immune system. Making use of this protein, the present inventors synthesized a covalent complex which is prepared by conjugating a Hub-antigen, N 2 ,N 6 -bis[N 2 ,N 6 -bis(3,4,5-trihydroxybenzoyl)-L-lysyl]-N-(2-aminoethyl)-L-lysine amide (TGDK), and Fetuin via covalent bond; as a result, the inventors could successfully developed a molecular mimicry mucosal vaccine against HIV/AIDS.
[0007] Thus, according to the present invention, there is provided an AIDS vaccine comprising a covalent complex of a Hub-antigen, N 2 ,N 6 -bis[N 2 ,N 6 -bis(3,4,5-trihydroxybenzoyl)-L-lysyl]-N-(2-aminoethyl)-L-lysine amide (TGDK), and Fetuin.
[0008] Preferably, the AIDS vaccine of the present invention is administered subcutaneously and/or orally and nasally.
Advantageous Effects of Invention
[0009] The AIDS vaccine of the present invention has the advantages capable of inducing mucosal immunity, defending against breakdown of the immune system due to HIV infection, preventing HIV from escaping the immune system on account of its high mutability, and prevent rapid infection of HIV.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1 , A and B, shows how X-protein (Fetuin) can be identified.
[0011] FIG. 2 shows the sequence of X-protein.
[0012] FIG. 3 shows the alignment between the amino acid sequences of SIV gp120 and X-protein.
[0013] FIG. 4 structurally compares X-protein with an HIV Env trimer, in which moieties in a conformation of gp120 that are homologous to X-protein (Fetuin) are indicated in yellow.
[0014] FIG. 5 shows UPA-like structures in the sequence of X-protein (Fetuin).
[0015] FIG. 6 shows the results of measurement of anti-gp 140 antibody titers.
DESCRIPTION OF EMBODIMENTS
[0016] The present invention will hereinafter be described in greater details.
[0017] The present invention relates to an AIDS vaccine comprising a covalent complex of a Hub-antigen, N 2 ,N 6 -bis[N 2 ,N 6 -bis(3,4,5-trihydroxybenzoyl)-L-lysyl]-N-(2-aminoethyl)-L-lysine amide (TGDK), and Fetuin.
[0018] The Hub-antigen to be used in the present invention is a glycerol polyethylene glycol polymer having a large number of primary amines on its surface that is produced by the following method: the active ester scaffold in HGEO-200NP (product of YUKA SANGGYO CO., LTD.) serving as the core structure is reacted with a small excess of HGEO-200PA (product of YUKA SANGGYO CO., LTD.), whereupon the molecule of HGEO-200PA forms a hub (a center from which others radiate in a wheel-like figure).
[0019] The N 2 ,N 6 -bis[N 2 ,N 6 -bis(3,4,5-trihydroxybenzoyl)-L-lysyl]-N-(2-aminoethyl)-L-lysine amide (TGDK) is a known compound and the method of its synthesis is disclosed in the above-mentioned Patent Document 1 (International Publication WO 2007/052641 A1), for example.
[0020] Fetuin is a protein synthesized in the liver from which it is secreted into blood. Fetuin is a kind of binding proteins that mediate transport and utilization of a wide range of transporter proteins in the blood circulation. Human Fetuin is synonymous with α2-HS-glycoprotein (AHSG), α2-HS, A2HS, AHS, HSGA, and Fetuin-A.
[0021] The method of synthesizing the covalent complex of the Hub-antigen, N 2 ,N 6 -bis[N 2 ,N 6 -bis(3,4,5-trihydroxybenzoyl)-L-lysyl]-N-(2-aminoethyl)-L-lysine amide (TGDK), and Fetuin is not particularly limited. An exemplary method of synthesis involves the procedure to be described later in the Examples section but this is not the sole method that can be employed. According to the method described later in the Examples section, activated polyethylene glycol (PNP4(10)) is first reacted with TGDK to synthesize an active ester of TGDK (i.e., PNP-TGDK). Then, this PNP-TGDK is reacted with the Hub-antigen to yield Hub-TGDK-PNP. Finally, this Hub-TGDK-PNP is reacted with Fetuin to thereby synthesize a covalent complex of Hub-TGDK-Fetuin.
[0022] The complex Hub-TGDK-Fetuin in the AIDS vaccine of the present invention may be used as it is or it may be formulated as a suitable form of preparation together with a pharmaceutically acceptable carrier. Exemplary carriers that may be used include excipients, binders, disintegrants, lubricants, and so on. The form of the preparation is not particularly limited and it may assume any forms such as liquids, tablets, pills, capsules, powders, granules, and syrups.
[0023] Examples of excipients that can be used include sugars such as lactose, sucrose, and glucose; starches such as potato starch and wheat starch; celluloses such as microcrystalline cellulose; inorganic salts such as anhydrous calcium hydrogen phosphate and calcium carbonate; polyethylene glycols and so on. Examples of binders that can be used include microcrystalline cellulose, pullulan, gum arabic, sodium alginate, and polyvinylpyrrolidone, as well as multifunctional polyethylene glycols. Examples of disintegrants that can be used include carboxymethyl cellulose, carboxymethyl cellulose calcium, hydroxypropyl cellulose, hydroxypropyl starch, and sodium alginate, as well as polyethylene glycols. Examples of lubricants that can be used include magnesium stearate, talc, and hardened oils. Examples of nanoparticle formers include cholesterol pullulan and multifunctional polyethylene glycols (MOF CORPORATION).
[0024] The route by which the AIDS vaccine of the present invention is to be administered is not particularly limited and it may be oral or parenteral route (for example, subcutaneous, rectal, intramuscular, nasal, or intravenous); a preferred route of administration is subcutaneous and/or oral and nasal route.
[0025] The amount of the active ingredient to be contained in the AIDS vaccine of the present invention (i.e., the covalent complex represented by Hub-TGDK-Fetuin) can be appropriately determined depending on the age, body weight, symptoms, etc. of the subject of administration or the patient; it is typically adjusted to range from 1 μg to 1000 mg/kg/dose, preferably from 10 μg to 100 mg/kg/dose.
[0026] The AIDS vaccine of the present invention may be administered together with an adjuvant. Any substance can be used as the adjuvant if it is capable of augmenting immune responses by being administered prior to the vaccine (antigen). Examples include not only antigenic adjuvants such as pasteurized microorganisms but also non-antigenic adjuvants such as alum (aluminum hydroxide potassium salt) and mineral oils. Jules Freund discovered in 1947 that when an aqueous solution of an antigen was mixed with an equal volume of oil (85% mineral oil and 15% surfactant) and injected in the form of an emulsion, an antibody was produced in an increased amount. Today, this is called incomplete Freund's adjuvant (IFA) and may be supplemented with whole cells of M. tuberculosis to form complete Freund's adjuvant (CFA). Other substances that exhibit the adjuvant effect are mineral acid salts such as aluminum hydroxide and aluminum phosphate. In addition, endotoxins, particularly lipopolysaccharides from Gram-negative bacteria, can markedly promote antibody production, with their active ingredient being present in lipid A. In the present invention, any one of the substances mentioned above can be used as adjuvants. The route of administration of the adjuvants is not particularly limited and may be oral or parenteral.
[0027] The distinctive features of the AIDS vaccine of the present invention are explained below.
[0028] (1) Induction of Mucosal Immunity
[0029] The TGDK (tetragalloyl D-lysine) derivative was discovered as a competitive inhibitor of UAE-1 (C-type lectin) and the present inventors successfully synthesized TGDK in both a solid and a liquid phase as an M cell targeting molecule essential to mucosal vaccines (Misumi et al., J. Immunol. 182, 6061-6070 (2009)). To be more specific, TGDK targeting at M cells is transcytosed to the lamina propria and binds to both NK-cells (natural killer cells), expressed by CD161, and NKT-cells (natural killer T-cells), mediating between the natural immune system and an acquired immune system, whereby the whole immune system is activated. In addition, the vaccine having formed a covalent bond with TGDK can induce systemic immunity and, with a small time lag, mucosal immunity even if it is injected subcutaneously, regardless of the type of the administered antigen.
[0030] (2) Defense against Breakdown of the Immune System Due to HIV Infection
[0031] In the process of infecting cells that play central roles in anti-HIV immunity, HIV makes use of CCR5 or CXCR4 (chemokine receptors) as a co-receptor. The present inventors focused on a specific conformational site of this co-receptor. The extracellular loop 2 (ECL-2) of either co-receptor forms a disulfide bond with ECL-1 and the resulting arch which is composed of 11 amino acid residues displays a specific conformation, called a UPA structure. When the disulfide bond forming this UPA structure is reductively cleaved and the arch breaks, HIV is no longer infective. In the molecules of the co-receptors to be utilized by HIV, the UPA structure is the most important moiety. As a preliminary step to induce a specific antibody against this UPA structure, a cyclic peptide mimicking it was synthesized to develop a cyclic antigenic vaccine. A mucosal immune tissue of a monkey immunized with this vaccine prevented breakdown of the immune system due to the immune tissue's destruction resulting from HIV infection, whereby the viral infection could be significantly suppressed (Misumi et al., J. Virol. 75, 11614-11620 (2001); Misumi et al., J. Biol. Chem. 278, 32335-32343 (2003)). According to the present invention, defense against breakdown of the immune system can be achieved by inducing a specific antibody against the special conformation of either co-receptor of HIV.
[0032] (3) Prevention of Easily Mutagenic HIV-Escape from the Immune System
[0033] HIV forms a trimer of its own envelope glycoprotein (spike protein) before it adsorbs to a cell and invades it. The mechanism by which HIV escapes the immune system on account of its high mutability may be explained as follows: a single base mutation of a virus gene leads to a mutation of a single amino acid residue, which is reflected in a “fluctuation” of the conformation of the viral envelope glycoprotein on account of the breaking of hydrogen bonds; a high-affinity neutralizing antibody evolved and induced in vivo in order to be specifically compatible can no longer recognize the “fluctuation” resulting that it does not react with the mutated antigen and fails to detoxify it. To prevent the HIV from escaping the immune system, the present inventors applied the following procedure in genetic chemistry as a means of facilitating the trimer formation: mutations in two amino acid residues (K514E and K524E) were inserted into the Ecto-domain gene of HIV Env protein to make it resistant to processing with an enzyme, thereby facilitating the trimer formation; there was also inserted a site capable of binding of the native protein via nickel; however, the sites subject to sugar chain modifications were left intact. A structural molecule that would reflect the conformational “fluctuation” due to a viral mutation was constructed in the following way: the conformational “fluctuation” due to a mutation of a virus was taken as a “fluctuation” of the molecular structure due to the breaking of hydrogen bonds in an aqueous solution of the polar solvent dimethylformamide; based on this assumption, the viral envelope glycoprotein was treated in an aqueous solution of the polar solvent dimethylformamide in a concentration-dependent manner (0 to 50% concentration in water) and the structure of the concurrently occurring “fluctuation” was covalently bonded to the activated Hub (radiant glycerol-polyethylene glycol)-TGDK antigen to prepare the desired molecular structure. The antibody induced by this antigen was independent of the viral strain and could neutralize a variety of viruses.
[0034] (4) Prevention of Rapid Infection of HIV
[0035] When immunized with a vaccine (pseudo-pathogenic antigen), humans will generally acquire immunity in 2-3 weeks (primary immune response). As the primary immune response subsides and memory immunity is formed, a human will immediately react to an invading, genuine pathogenic antigen and immunity is reactivated within a very short period of 12-24 hours (secondary immune response); as a result, the immune system wins the battle with the pathogenic antigen which is expelled, bringing the subject back to a healthy state. In the case of HIV, however, the virus sneaks into a gene of an immune cell during the 12-24 hour period of the secondary immune response and is incorporated into the gene to establish infection. Once incorporated into the gene, the HIV's gene cannot be expelled. In the process of infecting the immune cell, HIV proliferates as it destroys the cell and eventually the immune system loses the battle and AIDS is manifested in the human. This is why HIV must never be permitted to invade. To prevent rapid infection of HIV, a phenomenon called “induction of cross-immunity” is invoked in the mucous membrane, where initial infection takes place, to ensure that neutralizing antigens or antigen-binding antibodies are made available at all times; if this is achieved, the invading virus can be expelled with the aid of the natural immune system and the complement system; in addition, some design for maintaining killer T-cells need be worked out. In the present invention, the Hub-TGDK antigen was bound to the native HIV Env glycoprotein antigen and an escort antigen invoking induction of cross immunity was covalently bonded to prepare a multivalent covalent-bound antigen. Using this multivalent covalent-bound antigen, basic immunization was performed and, thereafter, antigens having moieties homologous to multivalent antigens other than the vaccine's native HIV Env glycoprotein antigen from a viewpoint of structural biology were used under memory immunity to construct on the mucous membrane a cross immunity framework capable of inducing antigens reacting with the HIV Env glycoprotein. According to the present invention, an immunity framework capable of invoking induction of cross immunity could be constructed in a monkey and the biological component Fetuin was discovered as an antigen capable of inducing cross immunity. By performing basic immunization with the viral glycoprotein antigen, the present inventors successfully developed a cross immunity inducing vaccine capable of producing an anti-HIV Env antibody with Fetuin instead of the viral glycoprotein antigen. As a result, the present inventors established a novel method of vaccination that would completely preclude HIV invasion into a local site in the mucous membrane.
[0036] The present invention will be illustrated more specifically by reference to the following Examples, however, the present invention is by no means limited by these Examples.
EXAMPLES
Example 1: Molecular Mimetic Mucous Vaccine for Biological Defense/Identification of Molecular Mimicry Moiety in Structural Biology Against HIV Envelope Glycoprotein (HIV Env gp 120)
[0037] Example 1-1: Identification of Molecular Mimicry Moiety
[0038] The present inventors previously created TGDK targeting to mucosal M cells (Misumi et al., J. Immunol. 182, 6061-6070 (2009)) and further created cyclic peptide antigens inducing antibodies against special conformations (undecapeptidyl arch; UPA) of the HIV co-receptors CCR5 and CXCR4 (Misumi et al., J. Virol. 75, 11614-11620 (2001) and Misumi et al., J. Biol. Chem. 278, 32335-32343 (2003)). The induced antibodies were capable of preventing breakdown of the immune system by HIV. In addition, to cope with the high mutability of HIV, the present inventors made attempts at obtaining antibodies having a wide range of binding specificity that would respond in spite of HIV mutation, in other words, in spite of slight changes in the antigen; to meet this end, the present inventors created a monomer and a trimer of the antigen to be used and predicted a conformational “fluctuation” due to HIV's mutation on the basis of the breaking of hydrogen bonds, and coped with the mutation-induced escape of HIV from the immune system. As a measure for facilitating the formation of a trimer of SIVmac239 Env protein, the two amino acid residues in the Ecto-domain at the C-terminal side of gp130 protein were altered to make this protein less susceptible to the action of an in vivo protease. A gene capable of producing a Ni-binding peptide was inserted at the C-terminus while the other portions were allowed to maintain a structure subject to sugar chain modifications similar to the native Env protein.
[0039] The resulting modified gene of SIVmac239 Env was transferred into simian Vero cells and a monomer and a trimer of SIVmac239 Env gp140 were constructed. In the study on designing an HIV/AIDS mucosal immune vaccine (Misumi et al., J. Immunol. 182, 6061-6070 (2009)), the present inventors discovered the induction of cross immunity in an immunization experiment using monkeys as follows. A vaccine was created by forming covalent bond with the Hub-antigen (glycerol-polyethylene glycol) to TGDK (agent targeting mucosal M cells), UPA (undecapeptidyl arch of CCR5; antigen inducing antibody against immunity destruction), CpGODN (B cell activator), and SIVmac239 Env (gp140 protein) as well as X-protein (Fetuin); after basic immunization of monkeys with this vacine, there occurred immune response which then subsided and when the anti-gp140 antibody titer decreased (after about one year and a half), the monkeys were immunized with a vaccine free of the gp140 antigen, whereupon the anti-gp140 antibody was induced despite the absence of the gp140 antigen; this anti-serum neutralized SIV and HIV, as well as members of their sub-species group. The present inventors discovered an antigenic molecule that would elicit the induction of cross immunity of interest and identified it to be Fetuin as the result of analyses by electrophoresis and MALDI-TOF/MS/MS ( FIGS. 1A and 1B .)
[0040] The same monkeys were subcutaneously injected with Fetuin alone and the production of anti-gp140 antibodies was confirmed. This protein is a ubiquitous protein which had an identical part, a homologous part, and a homologous moiety with respect to the monomer and trimer of SIVmac239 Env gp140 from a viewpoint of structural biology; being an extremely unique glycoprotein molecule, this antigen also had the same features with respect to HIV Env as well as SIV Env. The molecule was named an HIV molecular mimicry protein.
[0041] Example 1-2: Characterization of HIV Molecular Mimicry Protein
[0042] (1) Amino Acid Sequence and Chemically Modified Sites
[0043] The amino acid sequence of the HIV molecular mimicry protein is depicted in FIG. 2 . The HIV molecular mimicry protein has N-linked glycosylation sites, O-linked glycosylation sites, phosphorylation sites, six S-S bridges, and two free SH groups.
[0044] (2) Comparison Between the Amino Acid Sequences of HIV Molecular Mimicry Protein and HIV Env
[0045] The amino acid sequences of HIV molecular mimicry protein and HIV Env are depicted in FIG. 3 , in which the moieties likely to be subject to an addition of sugar chains are enclosed with a square.
[0046] (3) Comparison Between the Conformation of HIV Molecular Mimicry Protein and the Structure of HIV Env Trimer
[0047] The conformation of the HIV molecular mimicry protein was compared with the structure of HIV Env trimer and the results are shown in FIG. 4 , in which conformationally homologous moieties are indicated in yellow. As shown in FIG. 4 , homologous moieties were found to exist between the conformation of the HIV molecular mimicry protein and the structure of HIV Env trimer.
[0048] (4) Characterization of the Conformation of HIV Molecular Mimicry Protein Due to S-S Bridges
[0049] The sites of S-S bridges in the HIV molecular mimicry protein are shown in FIG. 5 . Two of the six S-S bridges formed an arch spanning 10 or 11 amino acid residues. The arch structures at these two sites were found to be homologous to the undecapeptidyl arch (UPA) of second extracellular loop (ECL-2) in the HIV-1 co-receptor CCR5 or CXCR4 (Misumi et al., J. Virol. 75, 11614-11620 (2001) and Misumi et al., J. Biol. Chem. 278, 32335-32343 (2003)).
[0050] (5) Summary of the Characterization of HIV Molecular Mimicry Protein
[0051] The HIV molecular mimicry protein was found to be a biological component having an extremely unique conformation in that it was quite homologous to the structure of the HIV Env trimer and that it also had the UPA structure of the HIV-1 co-receptor CCR5 or CXCR4.
Example 2: Preparation of HIV/AIDS Molecular Mimicry Mucosal Vaccine (MMMV)
[0052] Example 2-1: Chemical Structural Formula of TGDK
[0053] Chemical name of TGDK: N 2 ,N 6 -bis[N 2 ,N 6 -bis(3,4,5-trihydroxybenzoyl)-L-lysyl]-N-2-aminoethyl)-L-lysine amide (TGDK)
[0000] Gal: Galloyl group (trihydroxybenzoyl group)
[0000]
[0054] Example 2-2: Purification of TGDK (homogenous on MS chart; salt was removed by this procedure)
[0055] TGDK was metered in an amount of 12 !mole and after adding DMF (dehydrated) (500 ml) and ether (dehydrated) (1500 ill), the mixture was centrifuged at 15000 rpm for a minute. To the precipitate, 100% NMM (dehydrated) (600 i ll) was added and the mixture was sonicated for 1-2 seconds and then centrifuged at 15000 rpm for a minute. To the precipitate, 100% TFA (100 ml) was added and after adding ether (dehydrated) (900 ml) to the supernatant, the mixture was centrifuged at 15000 rpm for a minute. To the precipitate, DMF (dehydrated) (600 ml) and 100% NMM (dehydrated) (100-300 IA were added in that order. The pH of the resulting solution was confirmed as follows: to 1 ml of the solution, 4 la of water was added and pH measurement was done (pH 8-9). This gave a solution of purified TGDK in DMF (TGDK 12 !mole; weakly alkaline).
[0056] Example 2-3: Synthetic schemes of Hub-HGDK-Fetuin
[0057] In the following descriptions, activated polyethylene glycol (activated PEG, PTE-100NP; product of YUKA SANGYO CO., LTD.) is abbreviated as PNP4 (10), in which PNP refers to an activated ester.
[0058] (1) Synthesis of PNP-TGDK
[0059] To PNP4(10) (PTE-100NP, 18 μmole, 180 mg (total PNP, 18×4×0.9=64.8 μmole)) (180 mg), DMF (dehydrated) (900 ml) and purified TGDK (12 mole) (300-600 μl) were added in that order and the mixture was subjected to reaction at room temperature for 3 hours. The pH of the reaction mixture was measured as follows: to 1 μl of the reaction mixture, 4 μl of water was added and pH was confirmed (pH 8-9). This gave a solution of PNP-TGDK (1.5 ml, residual PNP: 18×3.6=64.8−12=52.8 μmole) (193 mg).
[0060] (2) Synthesis of Hub-TGDK-Fetuin
[0061] To the Hub-antigen (A8-49, 1 μmole, 168 mg, NH 2 49 μmole), DMF (dehydrated) (22 ml) and PNP-TGDK (12 μmole) (1.5 ml) were added in that order (residual PNP: 52.8-49=3.8 μmole). For pH measurement, 4 μl of water was added to 1 μl of the reaction mixture and pH was confirmed as described above (pH 7.6-8.4) (193 mg). The mixture was then left to stand for 12 hours at room temperature to effect reaction and after the end of the reaction, pH was measured and confirmed by the procedure described above (pH 7.3-8). This gave Hub-TGDK-PNP (residual amount: 3.8 μmole) (23 ml).
[0062] To this mixture, Fetuin (50 mg, 0.9 μmole)/PBS(-) (23 ml) (pH 7.4-7.8) was rapidly added dropwise (for a few minutes). The resulting mixture was stirred at room temperature overnight and dialyzed (Mw cutoff, 3500) under the following conditions.
[0000] 1. Against PBS(-), 2 L×three times, 24 hours
2. Against purified water, 2 L×three times, 24 hours
3. Against secondary water, 2 L×once, 12 hours.
[0063] The dialyzates were lyophilized to give lyophilized powder (about 130 mg of a Hub-TGDK-Fetuin powder).
[0064] Example 2-4: Sterilization
[0065] Sterilization with 70% EtOH produced visible gelation, so in the usual manner, the gel was stirred to homogeneity under sterilization.
Example 3: Administration to Monkey of the HIV/AIDS Molecular Mimicry Mucous Vaccine
[0066] (1) Experimental Materials and Method:
[0067] Six female cynomolgus monkeys (3 for the control group and 3 for the immunization) weighing about 3.5-4.5 kg were used in the experiment. The three monkeys of the immunization group were subcutaneously injected at both groins with 5 mg of the vaccine (Hub-TGDK-Fetuin; effective amount of Fetuin, ca. 1 mg) per monkey in 1 ml of PBS(-). Serum samples were prepared every two weeks.
[0068] (2) Measurement of Antibody Titer
[0069] The anti-gp140 antibody titer was measured by ELISA in accordance with the usual procedure.
[0070] (3) Results and Discussion
[0071] The results of the antibody titer measurement are shown in FIG. 6 .
[0072] In 2 weeks after the subcutaneous injection, the anti-gp140 antibody titer was found to elevate in the three vaccinated animals and in 4 weeks, the titer reached a maximum; in 8 weeks, it decreased to about 40-50% levels as compared to the maximum value, which have been maintained up until the present time. The anti-sera obtained at 8 weeks could prevent the infection with HIV-1 and SIVmac239. It should be noted that anti-UPA antibody activity was also observed in monkey #5.
SUMMARY OF THE EXAMPLES
[0073] (1) By single subcutaneous immunization with the Hub-TGDK-Fetuin vaccine, antibodies could be induced that reacted with both HIV-1 Env protein and SIVmac239 Env protein.
(2) Antibodies reacting with the special conformation (UPA) of the co-receptor CCR5 in HIV-1 were found to have been induced in the anti-serum of monkey #5; quite surprising result was found that the moieties formed by disulfide bonds in Fetuin fitted the UPA of CCR5 so well that Fetuin could induce antibodies against the special conformation of CCR5.
(3) Taken together, by inducing cross immunity in the mucous membrane, mucosal-associated HIV infection can be prevented.
(4) Immunization was first performed with the Hub-TGDK-UPA-CpGODN-gp140-Fetuin vaccine and after anti-gp140 antibodies disappeared from the blood, a booster was given by subcutaneous injection of gp140-free, Hub-TGDK-UPA-CpGODN-Fetuin, whereupon anti-gp140 antibodies could be produced. The similar result was confirmed by boosting with Fetuin alone through subcutaneous injection.
(5) Upon immunization of monkeys with the Hub-TGDK-Fetuin vaccine, the production of antibodies reacting with the gp140 antigen, namely, anti-gp140 antibodies, was confirmed.
(6) If induction of mimicry is established at the site of initial infection by means of an antigen having molecular moieties that mimic the HIV Env glycoprotein from a viewpoint of structural biology, a vaccine can provide complete protection against infection that outperforms the Jenner's smallpox shot.
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The present invention addresses the problem of providing an AIDS vaccine whereby mucosal immunity can be induced, the immune system can be defended against breakdown by HIV infection, HIV can be prevented from escaping the immune system by being highly mutable, and rapid HIV infection can be prevented. According to the present invention, provided is an AIDS vaccine comprising a hub antigen and a complex of N 2 ,N 6 -bis [N 2 ,N 6 -bis(3,4,5-trihydroxybenzoyl)-L-lysyl]-N-(2-aminoethyl)-L-lys-inamide (TGDK) and fetuin.
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RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. §119(e) from the co-pending U.S. provisional patent application Ser. No. 61/959,187, filed on Aug. 19, 2013, and titled “LIGHTING DEVICE WITH ASYMMETRIC LED CONFIGURATION.” The provisional patent application Ser. No. 61/959,187, filed on Aug. 19, 2013, and titled “LIGHTING DEVICE WITH ASYMMETRIC LED CONFIGURATION” is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to lighting systems. More specifically, this invention relates to Light Emitting Diode (LED) devices and systems.
BACKGROUND OF THE INVENTION
[0003] A light-emitting diode (LED) is a semiconductor diode that emits light when an electrical current is applied in the forward direction of the device, such as in a simple LED circuit.
[0004] The device is fabricated from layers of silicon and seeded with atoms of phosphorus, germanium, arsenic or other rare-earth elements. The layers of the device are called the die and the junction between the materials is where the light is generated. The electricity enters from one side of the die and exits out the other. As the current passes through the LED device, the materials that makes up the junction react and light is emitted.
[0005] LEDs are widely used as indicator lights on electronic devices and increasingly in higher power applications such as flashlights and area lighting. A LED is usually a small area (less than 1 mm 2 ) light source, often with optics added to the chip to shape its radiation pattern and assist in reflection. The color of the emitted light depends on the composition and condition of the semiconducting material used, and can be infrared, visible, or ultraviolet. The glow, color and wash of a lighting fixture with sets of LED arrays is sensitive to the angles of the LED arrays with respect to one and other.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a lighting system with angled extended arrays of LED light engines. Angled, herein, means that light emitting surfaces of the extended arrays of LED light engines are positioned at angles with respect to each other with a housing structure that form a lighting cavity. The extended arrays of LED light engines are coupled to bent, curved, contoured or angled support surfaces withing the housing structure, coupled to bent, curved, contoured or angled surfaces of the housing structure or a combination thereof.
[0007] The housing structure includes, for example, opaque surfaces and diffuse surfaces (lenses). Preferably, the extended arrays of LED light engines emit both upward and downward lighting through the diffuse surfaces of the housing structure.
[0008] The lighting system of the present invention includes one or more LED driver circuits in electrical communication with the extended arrays of LED light engines to provide dimming control of the upward and the downward lighting. In further embodiment of the invention the lighting system includes independently operable LED drivers in electrical communication with selected sets of the extended arrays of the LED light engines to provide independently controllable dimming of the upward and the downward lighting.
[0009] In accordance with the invention, the support surfaces within the housing structure of the lighting system with the extended arrays of LED light engines coupled thereto are adjustable. In some embodiments of the invention, angles of the support surfaces within the housing structure of the lighting system are adjustable, such that the angles of the light emitting surfaces of extended arrays of LED light engines are also adjustable with respect to each other.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows a schematic representation of a lighting system with extended arrays of LED light engines positioned at angles relative to each other on an adjustably angled support structure, in accordance with the embodiments of the invention.
[0011] FIG. 2 shows a schematic representation of a lighting system with extended arrays of LED light engines with LED drivers for independently controlling dimming of upward and downward lighting, in accordance with the embodiments of the invention.
[0012] FIG. 3A shows lighting system with an angled support structure housed within a lighting cavity having opposed opaque side walls, opposed top and bottom diffuser lenses and mounting features, in accordance with the embodiments of the invention.
[0013] FIGS. 3B-C show schematic representations of extended arrays of LED light engines, in accordance with the embodiments of the invention.
[0014] FIG. 4A shows a schematic representation of a lighting system with a movable or adjustable support and extended arrays of LED light engines coupled thereto, in accordance with the embodiments of the invention.
[0015] FIG. 4B shows a lighting system with a contoured housing structure, a support structure and extended arrays of LED light engines coupled to the contoured housing structure and the support structure, in accordance with the embodiments of the invention.
[0016] FIG. 4C shows a schematic representations of a lighting system with an alternative configuration that includes multiple angled support surfaces and extended arrays of LED light engines coupled to the angled support surfaces, in accordance with the embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] FIG. 1 shows a lighting system 100 that includes a housing structure that forms a lighting cavity 108 . The housing structure includes opaque side surfaces 101 and 101 ′ and top 105 and bottom 107 diffuser lenses. The lighting system 100 also includes support structure 103 that is bent, curved, contoured or angled. Extended arrays of LED light engines 123 and 125 are couple to top surfaces of the support structure 103 . An extended array of LED light engines 121 is also coupled to a center bottom surface of the support structure 103 .
[0018] The lighting system 100 provides upward and downward lighting through the top 105 and bottom 107 diffuser lenses. The extended arrays of LED light engines 121 , 123 and 125 are all powered by the same LED driver (not shown) or are alternatively powered by one or more independently controllable LED drivers to provide independent upward and downward and/or sideways dimming from the extended arrays of LED light engines 121 , 123 and 125 .
[0019] In accordance with the embodiments of the invention the angles or positions of extended arrays of LED light engines 121 and 123 are moveable or adjustable to new positions 123 ′ and 125 ′ by, for example, moving portions of the support structure 103 through one or more hinge features 111 and 111 ′, as indicated by the arrows 102 , 104 and 104 ′. The angle or positions of the portions of the support structure 103 are controlled manually or through a control device 109 that is in electrical or wireless communication with servo-motors or other mechanisms that drive the portion of the support structure 103 to move the extended arrays of LED light engines 121 and 123 to one or more selectable positions.
[0020] Referring now to FIG. 2 , a lighting system 200 includes a housing structure that form a lighting cavity 204 . The housing structure includes opaque side walls 210 and 201 ′ and top 205 and bottom 207 diffuser lenses. The lighting system 200 also includes a support structure 203 that is bent, curved, contoured or angled. On opposed top surfaces of the support structure 203 extended arrays of LED light engines 223 and 225 are mounted. Also, on opposed bottom surfaces of the support structure 203 extended arrays of LED light engines 227 and 229 are mounted. Further, on center top and bottom surfaces of the support structure 203 additional extended arrays of LED light engines 221 and 219 are also mounted.
[0021] The extended arrays of LED light engines 219 , 221 , 223 , 225 , 227 and 229 are all powered by the same LED driver circuit or are alternatively powered by one or more independently controllable LED driver circuits 231 and 233 to provide independent upward and downward and/or sideways dimming from the LED light engines 219 , 221 , 223 , 225 , 227 and 229 . For example, LED light engines 221 , 227 and 229 are powered by a downward dimming LED driver circuit 231 and the LED light engines 219 , 223 and 225 are powered by an upward LED dimming driver circuit 233 .
[0022] In accordance with the embodiments of the invention the angles or positions of portions of the support structure 203 are adjustable through one or more hinge features 211 and 211 ′ as described above with reference to FIG. 1 . The angles or positions of the portions of the support structure 203 are controlled manually or by a control device 209 that is in electrical or wireless communication with servo-motors or other mechanisms that drive the portions of the support structure 203 to move to one or more selectable positions.
[0023] FIG. 3A shows a linear or extended lighting fixture 300 that includes a bent, curved, contoured or angled support structure 313 housed within a lighting cavity 302 of a housing structure. The housing structure includes opaque side walls 301 , a top diffuser lens 305 and a bottom diffuser lens 307 . The bent, curved, contoured or angled support structure 313 supports any number of extended arrays of LED light engines that are controlled or dimmed by the same or different LED drivers, such as described with reference to FIGS. 1-2 . The lighting system 300 includes mounting features, such as cables 309 and 309 ′, that allows the lighting system 300 to be attached to or suspended from a ceiling or wall. As described above, the bent, curved, contoured or angled support structure 331 is stationary or adjustable to move the relative positions or angles of the light emitting surfaces of the extended arrays of LED light engines attached thereto within the lighting cavity 302 .
[0024] FIGS. 3B-C show schematic representations of extended arrays of LED light engines 325 and 350 , in accordance with the embodiments of the invention. The extended array of LED light engines 325 includes any number of aligned LEDs 331 , 333 , 335 , 337 and 339 that form a light emitting surface 326 that is substantially planar. The extended array of LED light engines 350 includes any number of staggered LEDs 361 , 363 , 365 , 367 and 369 that form a light emitting surface 351 that is substantially planar. It will be clear to one skilled in the art that any number of configuration of extended arrays of LED light engines that from a substantially planar light emitting surface are within the scope of the invention.
[0025] FIG. 4A show a lighting system 400 includes a housing structure that forms a lighting cavity 402 .
[0026] The housing structure includes opaque side surfaces 401 and 401 ′ with a top 405 and bottom 407 diffuser lens. The lighting system 100 also includes support structure 403 with angled surfaces. Extended arrays of LED light engines 415 , 417 and 419 are mounted, supported or otherwise coupled to the angled surfaces of the support structure 403 . In accordance with this embodiment of the invention the positions of the extended arrays of LED light engines 415 , 417 and 419 are moved within the lighting cavity 402 of the lighting system 400 by moving or rotating the support structure 403 , as indicated by the arrows 411 and 413 .
[0027] FIG. 4B shows a lighting system 425 that includes a housing structure that forms a lighting cavity 427 with a support structure 443 therein. The housing structure includes curved opaque side surfaces 426 with a top 445 and a bottom 439 diffuser lens. Extended arrays of LED light engines 431 and 437 are mounted, supported or otherwise couple to the curved opaque side surfaces 426 of the housing structure. Extended arrays of LED light engines 433 and 435 are also mounted, supported or otherwise couple to a surface of the support structure 433 . In operation, the relative positions of the light emitting surfaces of the extended arrays of LED light engines 431 and 437 and the extended arrays of LED light engines 433 and 435 are changed or adjusted by moving the support structure 433 up or down within the lighting cavity 427 , as indicated by the arrow 447 .
[0028] FIG. 4C show a lighting system 450 includes a housing structure that forms a lighting cavity 452 . The housing structure includes opaque side surfaces 451 and 451 ′ with a top 455 and bottom 457 diffuser lens. The lighting system 450 also includes support structures 453 and 453 ′ with angled surfaces. On the angles surfaces of the support structures 453 and 453 ′ extended arrays of LED light engines 473 , 475 , 473 ′ and 475 ′ are mounted or supported. In accordance with this embodiment of the invention the angles or positions of the extended arrays of LED light engines 473 , 475 , 473 ′ and 475 ′ are changed within the lighting cavity 452 by moving portions of the support structures 453 and 453 ′ through one or more hinge features 461 and 461 , as indicated by the arrows 454 and 454 ′. The angles or positions of the portions of the support structures 453 and 453 ′ are changed, adjusted or controlled manually or through a control device (not shown) that is in electrical or wireless communication with servo-motors or other mechanisms that move the portions of the support structure structures 453 and 453 ′ to thereby move the extended arrays of LED light engines 473 , 475 , 473 ′ and 475 ′ to selectable positions.
[0029] Still referring to FIG. 4C , the lighting system 450 includes a support structure 481 with extended arrays of LED light engines 483 and 485 mounted or supported thereon. In operation the positions of the light emitting surfaces of the extended arrays of LED light engines 483 and 485 relative to the light emitting surfaces of the extended arrays of LED light engines 473 , 475 , 473 ′ and 475 ′ are changed by moving the support structure 481 up or down within the lighting cavity 452 , as indicated by the arrow 447 .
[0030] Referring generally to FIGS. 4A-C , while the lighting systems 400 , 425 and 450 have been illustrated without LED driver circuits, its is understood that one or more internal or external LED driver circuit is required to power the lighting systems 400 , 425 and 450 . Further, while the lighting systems 400 , 425 and 450 have been illustrated without a mechanism for moving or changing positions or angles of light emitting surfaces of the extended arrays of LED light engines within lighting cavities 402 , 427 and 452 , it is understood any number of suitable mechanism are within the scope of the invention.
[0031] The present invention has been described in terms of specific embodiments incorporating details to facilitate the understanding of the principles of construction and operation of the invention. As such, references herein to specific embodiments and details thereof are not intended to limit the scope of the claims appended hereto. It will be apparent to those skilled in the art that modifications can be made in the embodiments chosen for illustration without departing from the spirit and scope of the invention.
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A lighting system with extended arrays of LED light engines is disclosed. The extended arrays of LED light engines are coupled to bent, curved, contoured or angled support surfaces withing a housing structure, coupled to bent, curved, contoured or angled surfaces of the housing structure or a combination thereof. Preferably, the extended arrays of LED light engines emit both upward and downward lighting through diffuse surfaces of the housing structure. In some embodiments of the invention the positions and/or angles of light emitting surfaces of extended arrays of LED light engines are adjustable within the housing structure.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of application Ser. No. 09/615,507 filed Jul. 13, 2000 now U.S. Pat. No. 6,759,476 and claims the benefit of provisional application Ser. No. 60/143,722 filed Jul. 14, 1999.
FIELD OF THE INVENTION
The present invention relates to a new composition of matter, a thermal control composite comprising a polymer and an endothermic agent. The endothermic agent is distributed, dispersed and suspended within and throughout the polymer and cured to form a composite for use in insulating, thermoprotecting, heat absorbing applications on the one hand and heat maintenance applications of all types on the other.
BACKGROUND OF THE INVENTION
All of the prior art known to Applicant teaches the use of endothermic agents in heat sinks wherein the endothermic agents are either coated, adsorbed or packed into various supporting structures.
For example, Applicant's first patent U.S. Pat. No. 4,449,916 discloses an endothermic agent adsorbed onto the fibers of the fabric matrix.
Applicant's second patent, U.S. Pat. No. 5,709,914 discloses an thermal storage compound packed into an open cell network, comprising natural, synthetic or metal fibers, spheres, particles, foams, or materials capable of being formed into a container suitable for enclosing and maintaining an item's high heat.
There are two very serious drawbacks to the prior art. First, leakage of the endothermic or thermal storage compound to the surrounding environment can occur, if the physical integrity of the various underlying supporting structures is somehow compromised. Such leakage will diminish the effectiveness of the heat sink material and may even lead to the harm and destruction of the item or material the heat sink material is supposed to protect, particularly if the endothermic or thermal storage compounds are harsh and corrosive.
Second, the underlying structures upon which the endothermic or thermal storage compounds are coated, absorbed, adsorbed or packed tend to be stiff and inflexible. The further coating, absorption, adsorption and packing of endothermic or thermal storage compounds on and within such structures will cause them to stiffen even more. This stiffening of the material renders them entirely unsuitable in applications where the heat sink materials must be flexible and in certain situations light, thin and drapeable.
It is therefore an object of the present invention to provide a composition of matter that can act as a heat sink/heat shield, but which will resist leaking the endothermic compound into the environment, by eliminating any possibility of a compromise of the structural integrity of the underlying carrier or support structure in the heat sink material.
It is another object of the present invention to provide a composition of matter for applications requiring a heat sink/heat shield which needs to be thin, flexible, drapeable, and/or conformable, while simultaneously protecting and insulating against high or low heat environments.
It is yet another object of the present invention to provide a composition of matter for applications requiring a heat providing material which will be thin, flexible, drapeable, and/or conformable, while simultaneously protecting and insulating against extreme cold environments.
The aforementioned objects, as well as others, will be found in detail in the following written disclosure.
SUMMARY OF THE INVENTION
The inventive composition of matter is a flexible thermal control composite. Said composite comprises a polymer and an endothermic agent. The endothermic agent is dispersed, distributed, and suspended in the polymer. Thereafter it is cured to form a “P”olymer “C”ontaining an “E”ndothermic “A”gent (PCEA) composite. This composite now has thermal control properties that make it suitable for a multitude of thermal control applications.
Natural or synthetic polymer may be softened or liquified by being (1) heated, (2) dissolved or (3) suspended in a plasticizer or solvent. When the polymer treated in any of these manners has an endothermic agent added to it, in very specific concentrations, distributed, dispersed, suspended therein and cured, a thermal control composite i.e. a PCEA is formed. Such PCEA is in essence capable of thermal control through its ability to absorb and store heat or through its ability to first absorb heat and then release it. It does so through the use of its endothermic compounds' own inherent thermodynamic, physical and chemical properties, i.e. their latent heats of fusion, hydration, formation, decomposition, vaporization, sublimation, or its allotropic and phase change reactions; while simultaneously completely eliminating any possibility of leakage of its endothermic compounds into the environment, as said agents become an integral part of the PCEA overall physical structure.
Thus, according to the present invention there is provided a PCEA thermal control composite comprising a natural or synthetic polymer and an endothermic agent. The PCEA thermal control composite can be thin, as for example a thin or a thick film, or molded as a thick PCEA brick. When the PCEA is a thin film, then the effective distribution of the endothermic agents within said polymer is 0.0001 to 1.2 gram of endothermic or thermal storage compound per square inch of PCEA, the PCEA having a thickness of 0.05 to 2.0 mil. On the other hand, where the PCEA is a thick film or molded structure, then the effective concentration of endotherm will be 0.05%–60% by weight endotherm in PCEA.
Full details of the present invention are set forth in the following description and illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a thin film PCEA formulated in accordance with the present disclosure;
FIG. 2 is a cross-sectional view taken along a line 2 – 2 ′ of the thin film PCEA in FIG. 1 ;
FIG. 3 is a perspective view of a thick film PCEA formulated in accordance with the present disclosure;
FIG. 4 is a cross-sectional view taken along a line 4 – 4 ′ of the thick film PCEA in FIG. 3 ;
FIG. 5 is a schematic of an extruding apparatus used in the extrusion of PCEA fibers;
FIG. 6 is a schematic of a second type of extruding apparatus used in the extrusion of PCEA fibers;
FIG. 7 is a perspective view of a PCEA fiber formulated and extruded in accordance with the present disclosure;
FIG. 8 and FIG. 9 are top plan views of PCEA materials assembled, woven or knit using PCEA fibers;
FIG. 10 is a schematic of a delivery and adhesion method of a small particulate PCEA onto a plastic substrate.
FIG. 11 is a schematic of a delivery and adhesion method of a large particulate PCEA onto a plastic substrate.
FIG. 12 is a schematic of the delivery of a PCEA into the inner walls of a home.
FIG. 13 is a perspective view of a container incorporating one of the embodiments of the PCEA;
FIG. 14 is a somewhat schematic, perspective view of a winter or hunting jacket, incorporating a preferred embodiment of the present inventive PCEA;
FIG. 15 is a cross-sectional view taken along 15 – 15 ′ of the jacket in FIG. 14 , showing another use of the PCEA, in the form of a mulch;
FIG. 16 is a somewhat schematic side view of the endothermic agent in the PCEA absorbing heat, thereby preventing the heat from reaching the heat sensitive device;
FIG. 17A and FIG. 17B are a somewhat schematic view of the inventive PCEA showing the recyclable endothermic agent first absorbing the heat ( FIG. 17A ) and then releasing the heat to the cold sensitive device, thereby maintaining the temperature of the cold sensitive device constant ( FIG. 17B );
FIG. 18 is a perspective view of a thin film PCEA formulated in accordance with the present disclosure and contacted to a thermally conductive material, only on one side;
FIG. 19 is a perspective view of a thin film PCEA formulated in accordance with the present disclosure and sandwiched between two layers of thermally conductive material;
FIG. 20 is a cross-sectional view taken along a line 3 – 3 ′ of the thin film PCEA/thermally conductive material in FIG. 18 , wherein the heat of the hot spot applied to one end of the PCEA is diffused across the entire surface of the PCEA and thereafter is absorbed by the PCEA's endothermic agent;
FIG. 21 is a cross-sectional view taken along a line 4 – 4 ′ of the thick film thermally conductive material/PCEA sandwich of FIG. 19 , wherein the heat of the hot spots applied to one end of the sandwich is diffused across the entire surface of the PCEA and thereafter is absorbed by the PCEA's endothermic agent.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The inventive thermal control composite i.e. the PCEA material 10 of FIG. 1 , FIG. 2 , FIG. 3 , and FIG. 4 shows the endothermic agent 11 dispersed, distributed and suspended within a polymer or plastic 12 .
(a) The Polymer or Plastic.
The plastic or polymer 12 of the PCEA material 10 may comprise any natural or synthetic polymer or a mixture thereof. Such natural and synthetic polymers comprise: all latexes including those used in paint; fluoropolymers such as various TEFLON® species, specifically polytetrafluoroethylene (PTFE), polyfluoroacetate (PFA) and fluoroethylpropylene(FEP) and other fluorinated plastic films having similar thermal stability, i.e. FEP: −200 DEGREES C. TO 200 DEGREES C. and PFA: −200 DEGREES C. TO 250 DEGREES C., that are well known in the art; expanded TEFLON®; high temperature fluoroelastomers such as VITON® and other highly thermoresistant polymers and plastics well known in the art; elastomers such as SILICONE® species specifically polydimethylsiloxane and polymethylphenylsiloxane and other siloxanes well known in the art; polyimides such as KAPTON®; POLYESTERS® such as MYLAR®; high density polymers such as TIVAR® and SPECTRA®; and other polyamides, polyarylates, polyetherimides, polyketones, polyphenylene oxides or sulfides, polyphenylsulfones, polystilfones, acetals, nylons, ABS, polyetherketones, phenolics, polystyrenes, cellulose, polycarbonates, polyethylenes, polypropylenes, acrylics, polyurethanes, polyvinyls, polyvinylchlorides, BRICKLITE®, polymeric and plastic materials well known to those skilled in the art of plastic materials. Preferably though the carrier plastic or polymer 13 should be TEFLON®, SILICONE®, or VITON®.
These polymers can be photo, thermally or chemically cured. More importantly however, they have a molecular structure consisting of long chains of mostly linear molecules, which after being relaxed by either controlled heating, dissolution or suspension in a plisticizer or solvent, provide the interstitial spaces, through which the endothermic or thermal storage compounds weave and are distributed prior to curing and the final formation of the PCEA.
(b) The Endothermic Agent.
An endothermic compound or agent is by definition a compound that absorbs heat. The endothermic agents of the present invention can be strict endotherms, i.e. they absorb and retain heat without releasing it into the surrounding environment. Or they can be recyclable endotherms, such as phase change materials, where they absorb heat initially and then they release the heat, if they are subjected to an environmental temperature differential.
The endothermic agents of the present invention comprise the following: oxidized and unoxidized polymers; oxidized and unoxidized homopolymers of ethylene polymer compounds; carbon monoxide-bonded copolymers; micronized polyethylene waxes such as stearic acid; waxes derived from petroleum; ethylene-bis-stearamide; N,N-ethylene-bis-stearamide; various tars; high molecular weight oils and hydrocarbons; polyvinyl alcohols; oxidized and unoxidized polyethylene homopolymers; carnauba wax; aluminum hydroxide, calcium hydroxide, potassium hydroxide, lithium hydroxide and the mixtures thereof; boric acid; dodecaborane, paraldehyde, paraformaldehyde, trioxane and the mixtures thereof; lithium formate, lithium acetate, lithium carbonate, calcium carbonate, silicon carbonate, magnesium carbonate, sodium bicarbonate and the mixtures thereof; salts of acetic acid, salts of formic acid, salts of boric acid and the mixtures thereof; lithium chloride trihydrate, lithium nitrate trihydrate, sodium carbonate decahydrate, sodium borate decahydrate, hydrated epsom salts, magnesium nitrate hexahydrate, beryllium sulfate tetrahydrate, sodium phosphate dodecahydrate, calcium chloride hexahydrate, zinc sulfate heptahydrate, magnesium chloride hexahydrate, sodium sulfate decahydrate, aluminum oxide trihydrate, aluminum sulfate decaoctahydrate, aluminum fluoride trihydrate, and the mixtures thereof; and any eutectic mixtures of any of these materials or families of materials including salts with melting points below 550 degrees Celsius.
These endothermic agents may be micronized and added to the polymer(s) after said polymer(s) have been relaxed by either controlled heating, dissolution or suspension in a plasticizer or solvent. The endothermic agents are then subjected to a mixing process by which they are distributed through and suspended in the polymer(s)' interstitial spaces, or in the interstitial spaces of the outer surface of the polymer(s), and fixed therein through final curing steps which result in the inventive thermal control composite i.e. the PCEA.
The ultimate effective concentration of the endotherm in the PCEA is determined on a case by case application basis by such factors as: the particular application i.e. whether the application requires the absorption of heat or the release of heat, the needed heat capacity of the application, the type of polymer used, the particulate size of the endotherm, and the needed flexibility and use of the novel PCEA. Thus, when seeking a drapeable PCEA having a thickness of 0.3 to 1.0 mil for a heat absorbing/heat protective clothing application the carrier plastic or polymer may be a fluoroelastomer, and the concentration of the endothermic agent or thermal storage compound may range from 0.0001 to 1.2 grams of endotherm per square inch of PCEA; with a preferred concentration of 0.01 to 0.06 grams of endotherm per square inch of PCEA.
On the other hand, when seeking a flexible PCEA having an observable thickness of, for example 1 inch, then the carrier polymer may be a silicone and the effective concentration of the endotherm in the PCEA will be 0.05%–60% by weight endotherm in PCEA; with a preferred concentration of 20% by weight endotherm in PCEA, for extreme maximum flexibility relative to the highest heat capacity.
The heat absorption/heat protective and/or the heat release/heat preservation properties of the present inventive PCEA materials become readily apparent in the Test Examples below, which represent various embodiments of the inventive PCEAs.
(c) Embodiments of the Invention.
A series of different PCEAs were prepared in accordance with the principles and requirements as described above. Specifically, natural or synthetic polymers were selected from the group of polymers set forth above. These polymers in turn were softened or liquified by (i) heat, (ii) solution in a solvent or (iii) suspension in a plasticizer, using conventional methods of softening and liquification already known in the art of polymer handling and processing.
To these softened or liquified polymers, in turn, were added an endothermic or a recyclable endothermic agent, preferably micronized, selected from the group of endotherms or thermal storage compounds set forth above, in specific concentrations. The polymer and endotherm combinations were then mixed thoroughly to insure the distribution, dispersal, and suspension of the endotherms in the polymers's interstitial spaces; said spaces being formed during the softening of the polymers' long chains of mostly linear molecules. The mixtures were then molded and cured into PCEA thin and thick films, PCEA bricks, various shaped PCEA mulches or extruded, or extruded and spun into PCEA fibers. Alternatively, the PCEA mixtures were contacted, painted and cured onto a polymer substrate, so that upon cooling, or evaporation of the solvent or the plasticizer, the PCEA is literally adsorbed only on the surface of the underlying polymer substrate.
These PCEAS were then tested to determine their heat absorbing capacities and performance, using standard calorimeter testing procedures. The results of some of these PCEA calorimeter tests were as follows:
TEST EXAMPLE I
Polymer/Boric Acid Film
POLYMER: VITON OR OTHER FLUOROELASTOMER
ENDOTHERMIC AGENT: BORIC ACID I.E. A STRICT ENDOTHERM.
LATENT HEAT OF DECOMPOSITION OF BORIC ACID: 400 CAL/G
THICKNESS OF FILM: 0.001 INCH
CONCENTRATION OF BORIC ACID IN THE PCEA: 0.03 GM OF BORIC ACID PER SQUARE INCH OF PCEA.
AMOUNT OF HEAT ABSORBED: 10,368 CAL/SQ.YD; 8 CAL/SQ. IN.
TEST EXAMPLE II
Polymer/Wax Film
POLYMER: VITON OR OTHER FLUROELASTOMER
ENDOTHERMIC AGENT: WAX I.E. RECYCLABLE ENDOTHERM CAPABLE OF ABSORBING HEAT AND THEN RELEASING IT.
LATENT HEAT OF FUSION OF WAX: 30 CAL/G
THICKNESS OF FILM: 0.001 INCH
CONCENTRATION OF WAX IN THE PCEA: 0.03 GM OF WAX PER SQUARE INCH OF PCEA.
AMOUNT OF HEAT ABSORBED: 166.4 CAL/SQ.YD; 0.9 CAL/SQ. IN.
TEST EXAMPLE III
Silicone/Boric Acid Film
POLYMER: SILICON
ENDOTHERMIC AGENT: BORIC ACID I.E. A STRICT ENDOTHERM LATENT HEAT OF DECOMPOSITION OF BORIC ACID: 400 CAL/G
THICKNESS OF FILM: 0.001 INCH OR 1.0 MIL
CONCENTRATION OF BORIC ACID IN THE PCEA: 0.05 GM OF BORIC ACID PER SQUARE INCH OF PCEA.
AMOUNT OF HEAT ABSORBED: 20 CAL/SQ. IN.
TEST EXAMPLE IV
Silicone/Endotherm PCEA
POLYMER: SILICONE
ENDOTHERMIC AGENT: HOMOPOLYMER I.E. A RECYCLABLE ENDOTHERM
LATENT HEAT OF FUSION OF THE HOMOPOLYMER: 80 CAL/GM.
PREPARATION: THE HOMOPOLYMER IS SUSPENDED IN A SILICONE GEL AND CURED.
RESULTS:
(A) THE FLEXIBILITY VALUES ARE A DIRECT FUNCTION OF THE RATIO OF ENDOTHERM TO SILICONE; (B) AT A HOMOPOLYMER CONCENTRATION OF 10% BY WEIGHT HOMOPOLYMER IN SILICONE PCEA THE AMOUNT OF HEAT ABSORBED IS 8 CAL/100 GMS OF PCEA; (C) AT A HOMOPOLYMER CONCENTRATION OF 20% BY WEIGHT HOMOPOLYMER IN SILICONE PCEA, THE AMOUNT OF HEAT ABSORBED IS 16 CAL/100 GMS OF PCEA; (D) AT A HOMOPOLYMER CONCENTRATION OF 35% BY WEIGHT HOMOPOLYMER IN SILICONE PCEA, THE AMOUNT OF HEAT ABSORBED IS 28 CAL/100 GMS OF PCEA; (E) AT A HOMOPOLYMER CONCENTRATION OF 60% BY WEIGHT HOMOPOLYMER IN SILICONE PCEA, THE AMOUNT OF HEAT ABSORBED IS 48 CAL/100 GMS OF PCEA. NOTE THAT THE PCEA IS BRITTLE AND FLAKES I.E. MORE SUITABLE FOR MULCH TYPE APPLICATIONS;
TEST EXAMPLE IV
Silicone/Boric Acid PCEA
POLYMER: SILICONE
ENDOTHERMIC AGENT: BORIC ACID I.E. A STRICT ENDOTHERM ENDOTHERM: BORIC ACID HAVING A LATENT HEAT OF FUSION OF 400 CAL/GM AT 140 DEGREES CELSIUS.
PREPARATION: THE BORIC ACID IS SUSPENDED IN A SILICONE GEL AND CURED.
RESULTS:
(A) THE FLEXIBILITY VALUES ARE A DIRECT FUNCTION OF THE RATIO OF ENDOTHERM TO SILICONE; (B) AT A BORIC ACID CONCENTRATION OF 20% BY WEIGHT BORIC ACID IN SILICONE PCEA THE AMOUNT OF HEAT ABSORBED IS 80 CAL/100 GMS OF PCEA.
TEST EXAMPLE V
Fluorocarbon/Carbon Monoxide Copolymer Film
POLYMER: FLUOROCARBON
ENDOTHERMIC AGENT: CARBON MONOXIDE COPOLYMER I.E. A RECYCLABLE ENDOTHERM
LATENT HEAT OF FUSION OF CARBON MONOXIDE COPOLYMER: 103 CAL/G
THICKNESS OF FILM: 0.001 INCH
CONCENTRATION OF CARBON MONOXIDE COPOLYMER IN THE PCEA: 0.06 GM PER SQUARE INCH OF PCEA.
AMOUNT OF HEAT ABSORBED: 6.2 CAL/SQ. IN.
NOTE: Carbon monoxide copolymer is a recyclable endotherm. This means that after it has absorbed 6.2 cal/sq.in. the PCEA can be used to transfer 6.2 cal/sq.in. to a cold sensitive device, animal, or human, which is being exposed to extreme cold conditions.
TEST EXAMPLE VI
Fluorocarbon/Homopolymer Film
POLYMER: FLUOROCARBON
LATENT HEAT OF FUSION OF HOMOPOLYMER: 80 CAL/G THICKNESS OF FILM: 0.001 INCH
CONCENTRATION OF HOMOPOLYMER IN THE PCEA: 0.06 GM PER SQUARE INCH OF PCEA.
AMOUNT OF HEAT ABSORBED: 4.8 CAL/SQ. IN.
NOTE: The Homopolymer is a recyclable endotherm. This means that after it has absorbed 4.8 cal/sq. in. the PCEA can be used to transfer 4.8 cal/sq. in. to a cold sensitive device, animal, or human, which is being exposed to extreme cold conditions.
TEST EXAMPLE VII
Silicone/Homopolymer:Carbon Monoxide Copolymer PCEA
POLYMER: SILICONE
ENDOTHERMIC AGENTS: HOMOPOLYMER AND CARBON MONOXIDE COPOLYMER I.E. RECYCLABLE ENDOTHERMS
LATENT HEAT OF FUSION OF THE HOMOPOLYMER IS 80 CAL/GM;
CARBON MONOXIDE COPOLYMER HAVING 103 CAL/GM; 50:50 RATIO HAS A LATENT HEAT OF FUSION OF 91.5 CAL/GM.
PREPARATION: THE HOMOPOLYMER AND CARBON MONOXIDE COPOLYMER ARE SUSPENDED IN A SILICONE GEL AND CURED.
RESULTS:
(A) THE FLEXIBILITY VALUES ARE A DIRECT FUNCTION OF THE RATIO OF ENDOTHERMS TO SILICONE; (B) AT ENDOTHERM CONCENTRATION OF 20% BY WEIGHT THE AMOUNT OF HEAT ABSORBED AND CAPABLE OF BEING RELEASED IS 1830 CAL/100 GMS OF PCEA.
It is clear from the above that PCEAs will perform superbly in applications directed to the absorption of heat. Furthermore, when the applications call for near isothermal conditions, i.e. two dimensional thermal conductivity or increased thermal conductivity along the surface plane, then any PCEA set forth in the examples above, or formed in accordance with the present disclosure, can be coupled with a metalized or thermally conductive material. This will diffuse the heat of hot spots across the entire surface of the PCEA. In fact, it was found that when a thermally conductive material was contacted to a 1.0 mil thick PCEA film comprising a homopolymer endotherm whose concentration was 0.02 gm of homopolymer endotherm per sq. in., the homopolymer (heat of fusion: 80 cal/gm) was capable of rapidly absorbing 2073.6 cal over 1 sq. yard; regardless of where the thermal flux was applied on the surface of the PCEA.
When the PCEA applications require some kind of ventilation and breathability, as for example in clothing, then the PCEA film can be pierced or provided with tears, holes, or openings. Such openings do not compromise the heat absorption performance of the PCEAs, nor do they affect the overall structural integrity of the application.
(d) Invention Applications.
The inventive PCEAs can be formed into thin and thick films. They may be drawn, molded or spun into fibers of all dimensions. They can be formed and chopped into PCEA mulch; the size of the mulch varying with the particular application. They can be molded into a brick or gasket. In fact, various modifications can be made to the present invention, as will be apparent to those skilled in the art; modifications which will depend on and become readily apparent from the particular applications for which the inventive PCEAs are intended for.
Thus, depending on the characteristics of the PCEA prepared, i.e. the heat capacity of its endothermic agent(s), the polymer(s) used, its form size and shape, the PCEA can be used for thermal control in protective clothing, winter clothing, boats, furniture, pipes, (living suits, hoses, auto interiors, fire walls, chemical processes, kitchen clothing and gear. Or, the PCEA can be used for environmental control in paint, pipes, tubs, walls as shown for example in FIG. 12 , shipping containers, medical devices, food, homes, aircraft, automobiles and tanks. Finally the inventive PCEAs can be used as protective pads in gloves, shoes, lab coats, fire gear and even ablative surgery; while, recyclable PCEAs, which are endotherms that make use of their latent heats of fusion, are ideal in use for dive suits and warm weather clothing, tents and gear.
In fact, the applications and uses of the inventive PCEA are infinite; limited only by the imagination of man and his ability to design new ways to protect in extreme environmental conditions, either hot or cold. Thus, the PCEA can also be formed into surfaces for use tinder carpets or adhered to carpets using a method such as that portrayed in FIG. 10 and FIG. 11 in an effort to keep homes in as near an isothermal situation as possible. On the other hand, the PCEA may also be used as a means of camouflage by the removal of the heat signature of military combat gear, troops and military vehicles; or as a flexible thermal shield for the protection of spacecraft electronics and satellites from the harmful effects of solar radiation. Finally, PCEA fibers can be knit, spun or woven into protective cloth as shown in FIG. 8 and FIG. 9 , whose applications can also be infinite.
Accordingly, while only a few embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made theretinto without departing from the spirit and scope of the invention as disclosed herein.
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A flexible thermal control composite comprising a natural or synthetic polymer and an endotherm dispersed, distributed and suspended within said natural or synthetic polymer i.e. “P”olymer “C”ontaining an “E”ndothermic “A”gent (PCEA). The PCEA can be formed into thin and thick films. It can be drawn, molded, extruded and spun into fibers or all dimensions. It can be formed and chopped into PCEA mulch. Irrespective its final form, the PCEA can be used in insulating, thermoprotecting, heat absorbing applications on the one hand, and heat maintenance applications of all types on the other.
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This is a division of application Ser. No. 07/911,472, filed Jul. 10, 1992, now U.S. Pat. No. 5,295,997.
BACKGROUND OF THE INVENTION
The invention relates to a process for the production of a cotton-based, lightweight and washable, nonwoven cloth. It also relates to the cotton-based, durable or semi-durable, washable cloths thus obtained.
A process for the production of nonwoven cloths has been described in the documents U.S. Pat. Nos. 3,214,819, 3,485,706 and 3,508,308, in which process the cohesion and the interlacing of the elementary fibers with one another is obtained not by mechanical means but by means of a plurality of jets of water under pressure passing through a moving fleece or cloth and, like needles, causing the fibres to intermingle with one another. These nonwoven cloths are known in the literature under the English term "spunlace cloths" or "spunlace". It would therefore not serve any purpose to describe them here in detail. These "spunlace" cloths are essentially defined by the fact that their consolidation results from hydraulic interlacing.
Moreover, it is well known to produce cotton nonwoven cloths by a dry method or even by a wet method, that is to say papermaking method. These cotton nonwoven cloths are essentially desired for their absorbent power. They are therefore disposable, in particular for hygiene, medicine or as a wipe.
The production of "spunlace" cloths in cotton has been proposed. In this way, lightweight materials are obtained which are very soft to the touch and slightly fluffy. Unfortunately, these cloths have a poor resistance to abrasion when wet. In other words, from the time they are wetted, these cotton-based "spunlace" cloths lose their body and their textile handle, which are, however, highly desirable. It is therfore impossible to wash these cloths, which disintegrate very rapidly as soon as they are washed for the first time.
Now, however, the market increasingly calls for cotton-based lightweight cloths capable of being washed several times, while retaining their textile touch and body.
In order to overcome these disadvantages, it has been proposed to introduce binders, in particular latexes, into these cotton "spunlace" cloths. Unfortunately, this process is not satisfactory since the incorporation of such binders considerably changes the touch and the body of the products and also their absorption capacity, as well as the suppleness.
For all of these reasons it is not possible to date to produce washable cotton "spunlace" cloths while retaining the main features of their mechanical and textile properties, which are increasingly desired.
The present invention mitigates these disadvantages.
SUMMARY OF THE INVENTION
It provides an improved process for the production of cotton "spunlace" cloths, which process makes it possible economically and reliably to obtain such washable cotton "spunlace" cloths, which retain their mechanical and textile properties even after several washes (five washes and more).
The process according to the invention for the production of a "spunlace" nonwoven cloth based on cotton fibers, which comprises continuously:
advancing a cloth based on cotton fibers,
interlacing these fibres with the aid of a plurality of water jets under pressure,
drying said interlaced cloth,
and, finally, taking delivery of the "spunlace" cloth thus obtained,
is characterised:
in that, after interlacing and before drying, the free water contained in the interlaced cloth is drained;
then said drained cloth is impregnated using an aqueous solution of a polyamide-amine-epichlorohydrin (PAE) resin in an amount, measured as solids, of 0.2% to 1% of the weight of the cotton fibers;
and, after having expelled the excess solution, the impregnated cloth is dried at a temperature sufficient to at least initiate the crosslinking of the PAE resin deposited.
In other words, the invention includes preparing a "spunlace" cloth based on cotton fibers in a known manner, then, after interlacing but before drying, draining said wet cloth and then impregnating with an aqueous solution of a PAE resin in an amount of 0.2 to 1% of the weight of the cotton fibers. After having initiated and completed the crosslinking of the PAE resin, a washable "spunlace" cloth which has excellent mechanical properties, a good handle, good body and good suppleness, even after several repeated washings, is obtained in an unexpected and surprising manner.
BRIEF DESCRIPTION OF THE DRAWING
The appended single FIGURE shows diagrammatically an installation for the implementation of the process according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
Advantageously, in practice
the base cloth consists mainly of cotton. The cotton fibers may be mixed with fibers of a different type, in particular cellulose fibers (viscose, linen, ramie and the like,) or even synthetic fibers (such as polyamide, polyester or poly propylene) in particular in order to improve the mechanical properties of the cloth. The length of these fibers may be the same as or different from that of the cotton fibers;
The base cloth based on cotton fibers has a weight of between 30 and 300 g/m 2 . It has been observed that if this weight is less than 30 g/m 2 the cloth, or more accurately the fleece, has few bonds and little coherence and is difficult to handle and to interlace by jets of water. Similarly, if the weight exceeds 300 g/m 2 , the process lacks economic interest. It has been observed that good results were obtained with base cloths having a weight of between 30 and 100 g/m 2 .
The interlacing by a jet of water under pressure is carried out in a known manner (pressure between 30 and 250 bars), the jets being directed at one or both sides of the base cloth.
Draining of the free water contained in the wet interlaced cloth is carried out by padding or suction. All of the free water, that is to say the water contained between the cotton fibers, with the exclusion of the water included in these cotton fibers (absorbed water), is thus expelled.
Impregnation with the PAE solution is carried out by any appropriate technique, such as impregnation, padding, full bath or spraying. The amount of resin deposited, in dry cross-section, is between 0.2 and 1. It has been observed that if this amount is less than 0.2% no significant improvement is obtained on the other hand, if this amount exceeds 1% no improvement is observed, while the cost is increased to no effect. The amount deposited is variable depending on the intended applications and the washability criteria and depending on whether it is desired to obtain semi-durable products (capable of being washed three to ten times) or durable products (ten washings and more). It has been observed that good results were obtained with amounts on the order of 0.4 to 0.8%.
After impregnation the concentration of the aqueous PAE solution is adjusted by padding and the impregnated "spunlace" cloth is then dried continuously, said drying being carried out by any known means, such as an oven with a through-flow of air, cylindrical driers, a stenter frame, infrared lamps and the like. It is essential to heat to a temperature sufficient to give rise to crosslinking of the PAE resin or, more accurately to trigger this crosslinking. In practice, drying is carried out at a temperature of at least 140° C.
After collecting the cloth on a reel, crosslinking is allowed to proceed on the worked material, for example by storing for one to two weeks at ambient temperature.
As is known, polyamide-amine-epichlorohydrin (PAE) resins are generally obtained by a polycondensation reaction of a carboxylic diacid and a triamine, followed by reaction of epichlorohydrin with the low molecular weight chains of the polyamide-polyamine. Epichlorohydrin converts the secondary a/nine groups to tertiary amine or even quaternary ammonium groups and then introduces branching points into the chain. The result is polymers of low molecular weight which are slightly branched, in particular in order to be able to be readily soluble in water, and have a cationic character, even for slightly alkaline pHs, and crosslinking possibilities.
It is thought that the wet strength (WS) obtained results from groups in these resins which are capable of being involved, that is to say:
secondary and tertiary amine groups;
epoxy groups, and
azetidinium groups.
The latter two groups are capable of giving covalent bonds by reaction with other groups in the resin (homocrosslinking), or with functional groups in the cotton fibers (cocrosslinking). The development of the wet strength is accelerated by heating to 140° C. or above. In fact, it has been observed that the wet strength (WS) of the "spunlace" cloths according to the invention is obtained particularly on drying and that this strength continues to develop during storage. This must result in part from the fact that curing of the resin continues during storage.
The polyamide-amine-epichlorohydrin (PAE) resins are well known. These resins are available commercially, in particular under the following trade names:
NADAVIN LTS or LTN-A from the German company BAYER, and
KYMENE 557 H or 709 from the American company HERCULES.
These resins are currently used for papermaking, by incorporating them in the pulp in the pulper with a view to giving the paper a good wet strength, in particular for the production of teabags. In this technique the resin is therefore introduced into the pulp in the wet and not onto a dry fleece. Unfortunately, the papers obtained have no resistance to washing, which is not troublesome for the envisaged application, which is disposable use.
It is surprising to find that the selection of a "spunlace" cloth from the various known cotton-based cloths, in combination with binding with a very small amount of a particular resin, that is to say PAE resin, makes it possible successfully to resolve a problem which has existed for a long time, that is to say the possibility of producing washable "spunlace" cloths which, even after several repeated washings, retain not only all of their mechanical properties but also all of their textile characteristics of touch, drapability, suppleness, and the like.
The way in which the invention may be implemented and the advantages which result therefrom will be better apparent from the implementation examples which follow, supported by the appended single figure.
In this continuous installation, the following references have the indicated meanings:
(1): a base cloth of cotton fibers
(2): the first binding unit of the hydraulic binding machine, such as that sold by the present assignee under the tradename JETLACE;
(3): the second hydraulic binding unit of the same machine, for interlacing the other side, in order to improve the abrasion resistance; in practice, the amount of energy transferred by the water jets of the binding units (2, 3) to the cloth (1) is adjusted to a value of between 0.2 and 1.1 kWH per kilo of fibers and the diameter of the water jets is adjusted to a value of between 100 and 150 microns, at a pressure of between 30 and 250 bars;
(4): the interlaced wet cloth obtained;
(5): the padding unit for expelling the free water contained in the wet "spunlace" cloth (4) (absorbed residual water of the order of 30%);
(6): unit for impregnation with the aqueous PAE solution;
(7): the "spunlace" cloth impregnated with PAE;
(8): the drying unit, for example heated to 140° C.;
(9): the washable "spunlace" cloth obtained, wound in the form of a reel (10).
The interlacing (2, 3) and impregnating (6) units may be combined with suction tanks intended to remove some of the water, it being possible for these tanks to replace the padding unit (5).
EXAMPLE 1
A "spunlace" cloth (4) weighing 35 g/m 2 and based on carded bleached cotton fibers is prepared in a known manner using the installation (2, 3). The pressure of the injectors (2, 3) is adjusted to 90 bars and the diameter of the injection nozzles is adjusted to 0.12 mm. The speed of advance of the cloth (1) is adjusted to 60 m/min. After drying the cloth (4), followed by immediate winding (conventional technique), a "spunlace" cloth is obtained which has an excellent handle and a good touch but which disintegrates entirely from the time of the first wash and may therefore not be reused.
The cloth is therefore a disposable cloth.
EXAMPLE 2
Example 1 is repeated. However, the wet cloth (4) obtained is impregnated, after drying (5), by padding with an aqueous solution of a PAE resin marketed by HERCULES under the trade name "KYMENE 557 H". The amount deposited (measured as solids) is adjusted to 0.8% by means of padding. Drying is carried out in (8) on a cylinder which has a through-flow of air at 150° C. and the impregnated "spunlace" cloth (9) obtained is then stored for two weeks in order to complete crosslinking/curing of the PAE resin.
After eight customary domestic washes at 70° C. in a washing machine using water to which commercial detergent is added, no significant deterioration either in the mechanical properties (abrasion resistance, tear strength) or in the textile properties (touch, body, suppleness) of the impregnated "spunlace" cloth (9) is observed.
EXAMPLE 3
Example 1 is repeated, reducing the amount deposited to 0.2%.
The impregnated "spunlace" cloth obtained (9) is able to withstand only three domestic washes.
EXAMPLE 4
Example 2 is repeated, replacing the cloth (1) by a papermaking sheet based on cotton fibres and weighing about 80 g/m 2 .
The PAE resin does not fix on the cotton fibers and does not penetrate into the sheet, so that the latter is not washable and has no textile property in respect of body or touch.
The process according to the invention has numerous advantages compared with those marketed to date. The following may be mentioned:
the absence of change in the characteristics of the cotton-based "spunlace" cloth, which retains all of its textile properties, in particular in respect of touch, suppleness, body and absorption;
good retention of its textile properties and mechanical properties, even after several repeated washes; and
good improvement in the wet properties.
Consequently, these cloths may be successfully used in numerous fields of application where a textile touch, mechanical properties and the possibility of being washed several times are desired simultaneously. The following may be mentioned: wiping cloths, table and household linen, the production of clothing, in particular working clothes, linings, and the like.
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A spunlace non-woven cotton-based cloth which can be repetitively laundered without significant deterioration in the mechanical and textile properties thereof, including cotton fibers impregnated with polyamide-amine-epichlorohydrin resin. The resin is present in an amount of 0.2% to 1.0% by weight, based on the weight of the cotton fibers.
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This invention relates to the field of wiring harnesses or wiring networks, sometimes referred to pigtails. The invention more specifically is a device that permits and performs the automation of the fabrication of the wiring networks.
BACKGROUND OF THE INVENTION
Wiring harnesses typically interconnect two or more connectors, which then may be mated with other connectors. The requirements for the wiring network may be such that the wires do not connect with the same relative position on each of the connectors and the connector on one end of the network may be a double row connector while the connector on the other end may be a single row connector.
These requirements have heretofore dictated that the networks be hand wired. Also, the potential use of a flat ribbon type cable is eliminated due to the requirement that some conductors cross others.
SUMMARY OF THE INVENTION
Connectors are positioned at spaced apart positions separated by the requisite distance and a die positioned therebetween. The die acts to guide the wires from an entry point to an exit point. The wires are then gang fed or individually fed into the entry point and through the die to the exit point and beyond. The wires are then trimmed to length and pressed into the insulation displacement connector to complete the connection.
The die may be as simple as a tube with the ends positioned appropriately, or a block of material with grooves cut therein to act as guiding channels. The grooves may be formed in any desired deviation to route the wire to the desired exit point. With the use of either deflectors or a separator between the die parts, the wires may be crossed over other wires to position the ends at positions as desired.
It is an object of the invention to permit automation of the fabrication of wiring networks.
It is a further object of the invention to permit efficient interconnection of connectors in a non uniform pattern.
DRAWING
FIG. 1 is a drawing showing the positional relationship of the elements of the wiring harness and the wire feeding, guiding and cutting mechanisms.
FIG. 2 is an illustration of the die for guiding the wires, of the device of FIG. 1, wherein the channels are of serpentine shape and have a crossover point and deflectors to aid in the feeding of the wires.
FIG. 3 is an illustration of the die with a separator member positioned between the two halves of the die.
FIG. 4 illustrates a die for the feeding of shunts.
FIG. 5 illustrates an alternate embodiment of a shunt die.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, it is seen that the connectors 10, 11 are positioned at spaced apart locations which are dictated by the length of the wiring network to be fabricated. The connectors 10, 11 may be the same or may be of different configuration, depending upon the type device to which they respectively connect. To guide the wires 12 from a terminating point adjacent one of the connectors 10, 11 to a terminating point adjacent the other connector 11, 10 a die 14 is positioned with entry and exit points slightly above the top plane of the connectors 10, 11. The die 14 is comprised of a top plate 16 and a bottom plate 18. One or both plates 16, 18 may have grooves or channels 20 cut or formed in the plate. The grooves 20 may traverse the plate 16 or 18 from one end to the other in a straight line or deviate in a serpentine shape as required by the electrical circuitry to which the connectors 10, 11 will connect.
In order to feed the wires 12, a wire guide 22 is positioned adjacent one of the connectors 11 and aligned with the entry point of the die 14. The wire guide 22 may conveniently be a single guide tube 24 or a gang guide where several passages are formed into a single member. The wire guide 22 provides the proper placement of the wire 12 for smooth entry into the die 14. The wires are pushed through the wire guide 22 by a wire pusher 26. Wire pusher 26 may comprise a pair of feed rolls 28 positioned to form a pressure nip 29 therebetween. The wires 12 are fed to the nip of the feed roll 28 pair and as the feed roll pair 28 drives, the wires are pulled from the wire supply 30 which may take one of several forms, such as a reel, coil or discrete short lengths.
To sever the wires 12 at the point where the wires 12 cross the connector 11, a cut off 32 is provided. The cut off 32 may take a number of forms but is most advantageously configured as a shear.
The connectors 10, 11 may typically be of the insulation displacement connector type, commonly referred to as IDC's. The use of IDC's allows the easy insertion of the wires 12 into the connectors 10, 11. Gang wire presses 13 are readily available from connector manufactures, which are capable of forcing the entire set of wires 12 into the connectors 10, 11 in a single operation. Such a gang wire press 13 may be positioned over each connector 10, 11 so that the wires 12 may be pressed into the connectors 10, 11 after the wires 12 are severed from their supplies 30.
A very significant key to the flexibility of a device as is described herein is the die 14. Referring to FIG. 2, the die 14 is illustrated as a plate 18 having channels 34, 36 formed in the top surface thereof, to guide the wires 12 and route them to terminating positions at one connector, which do not necessarily correspond to the positions at the connector. The channels 34, 36 illustrated are illustrative of several characteristics that the channels may have. The channel 34 is a serpentine channel and displaces the wire exit laterally from the entry point. Additionally, channel 34 crosses channel 36. The depth of the channels 34, 36 is a matter of design choice, but must be in excess of two wire diameters at the point of crossover.
The problem of wire jamming in the channels 34, 36 is addressed by the use of deflectors 38, 40. Deflectors 38, 40 may be positioned in or formed in the channels 34, 36. The deflectors 38, 40 are provided in the channels 34, 36 to cause one of the wires 12 to be raised up from the floor of the channel 34 while the wire in channel 36 is caused to deflect downwardly to pass under the wire 12 in channel 36.
FIG. 3 illustrates another embodiment of the die 14. In this embodiment, the parts of the die are a bottom plate 42, a top plate 44 and a separator plate 46. The channels 48 in the bottom plate will tend to be channels all deviating in the same direction or at least not crossing other channels. The channels 50 in the top plate 44 will likewise all tend to deviate in the opposite direction, to that of the channels 48, or at least not crossing other channels 48. The separator plate is positioned between the two plates 42, 44 and in effect forms two separate and distinct die sets. Crossovers in this type die do not intersect and therefore do not require that the wires be deviated as in the die 14 as shown in FIG. 2. The two approaches shown in FIG. 2 and FIG. 3 may be combined in a single die and handle more complex routing requirements.
FIG. 4 is the illustration of a shunt die 60. The shunt die 60 may be formed as part of a die plate and could be used most advantageously in the type of die that is illustrated in FIG. 3, having a separator plate 46. If room does not permit the inclusion of a shunt die 60 in one of the main die plates 42, 44, the shunt die 60 may be piggy backed on the top plate 44 of the die 14. The shunt die 60 in FIG. 4 is a block 62 which has had a loop channel 64 cut therein. Thus, when the wire 12 is fed into the shunt die 60 the wire 12 will loop back to a position on the connector adjacent the entry point to the shunt die 60. Thus, two positions on the same connector 10 can be connected or shunted. The shunt die 62 may be opened by an air cylinder, not shown, or other mechanical device to permit the removal of the loop from the die 60.
In order to accommodate different entry point levels, the positioning of the die 14 may be varied such that a first level of channels may be presented to the wires 12 and then a second level of channels may be presented to the wires 12. This technique will simplify the die 14 for particularly complex routings. This technique is also applicable to the use of a piggy backed shunt die 60.
In the event that multilevel dies 14 are used, the die positioning means 64, used to open and close the die 14 may be adapted to shift the die 14 in a direction normal to the plane of the die 14. The die positioning means 64 may be a hydraulic or pneumatic cylinder or cylinders which extend or retract to move the top and bottom plates 42, 44. If a separator plate 46 is used, it may be positioned on a support 47 such that it remains relatively fixed, or the support arm 49 may be weak enough to flex permitting the separator plate to move slightly to accommodate the movement of the plates 42, 44. Alternatively, the separator plate may be fabricated out of sheet spring stock and an arm extended to allow for such movement. Thus, the die 14 with a piggy backed shunt die 60 may be shifted to form the shunt as a separate step from the feeding of the wires 12 for the main network.
The wire pusher 26, as in FIG. 1, may be provided as a series of separate wire pushers, each operating on a single wire 12. With each wire 12 individually fed, the length of the wire 12 may be controlled to avoid waste and selected wires 12 may be fed independent of others and thus provide increased flexibility in the forming of wiring networks where it is desirable to shift a multi level die 14 to accommodate multiple levels of entry points to the die 14.
OPERATION OF THE INVENTION
Connectors 10, 11 are positioned at their desired position and the die 14 brought by the die positioning means 64 into the space between the connectors 10, 11, in effect closing the die 14. The entry points to the die 14 are located aligned with the axis of the wires 12. The wire pusher 26 is then activated to push the wires 12 through the wire guide 22 and into the die 14. The wire 12 is pushed until the the wire 12 extends through the die 14 and extends over the connector 10 adjacent the exit point of die 14. The wire cut off means 32 is activated to sever the extended portion of the wires 12 from the wire supply 30. The gang wire presses 13 are forced against the wires 12 and the connectors 10, 11 to connect the wires 12 with the connectors. The die 14 must now be opened to allow the wires 12 to be moved from the work station. If the die is provided with a separator plate 46, the wires 12 will be on one side or the other of the separator plate 46 and may be moved in a direction parallel to the plane of the separator plate 46.
If a wiring harness is sufficiently complex to warrant the use of a multi level die 14 which needs to be shifted to align different levels of entry points with the wires 12, several wire feeding operations may take place at different levels, prior to the use of the gang wire press 13 to effect the connection with connectors 10, 11.
After the die 14 is separated, the network with the attached connectors 10 is moved out of the work station and the die 14 closed and the process repeated.
The positioning of the connectors 10, 11 may be accomplished by conventional means such as vibrator bowls and chutes, and the operations of the die positioning means 64, cut off 32 and wire pushers 26 may be controlled by a computer or special purpose electronic controls.
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A device for automated manufacture of wiring harness is described. The device feeds the wires through a number of channels in a die to position the wires at the proper termination points and then terminates the wires in connectors. The wiring harness assembly device permits the automated assembly of wiring harnesses which have wires which interconnect the connectors at positions which do not positionally correspond.
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BACKGROUND OF THE INVENTION
The present invention relates to a method for both-side copying wherein the desired number of copies can be made even when copy sheets are jammed while copying the reverse side of a document having images on its both sides.
When copying a plurality of documents on many of the conventional copying machines, a user is required to place a document on a document glass plate one by one for replacement and it is a tough job to keep standing for the replacement of documents especially when the number of documents is large. Recently, therefore, there has been developed and has been put to practical use an automatic document feeding device wherein the plural documents stacked and positioned at a prescribed location can be conveyed one by one automatically onto the document glass plate and copied.
Among documents, incidentally, there are many of so-called both-side documents which have information desired to be copied on both sides thereof and an automatic document feeding device that can be used even for such both-side documents has been developed. In such automatic document feeding device for the both-side document, one side of the document is copied and then the document is turned upside down for copying its reverse side and is delivered, thus the documents are delivered in succession after being copied for both sides. Hereinafter, the first side of the document firstly copied is called as a obverse side and the second side of the document secondly copied is called as a reverse side. When a sheet jamming of a copy sheet (so-called a jam) takes place inside a copy machine while copying the reverse side of the both-side document onto the copy sheet in the copy machine employing aforesaid automatic document feeding device of a document-turnover type capable of reversing the side of document to be copied, it is necessary to clear the jam such as removing the jammed sheet and to continue producing the remaining copies for desired number of copies and then place the document manually on the document glass plate again to make copies corresponding the number of failed copies caused by the jam. This work is very troublesome.
There are some occasions wherein copy sheets are jammed while copying plural both-side documents or copying is desired to be discontinued for some reasons. In such a case, a document is delivered once, and it is no problem to deliver without taking any action when copying the obverse side of the document but it is a problem to deliver the document without taking an action when copying the reverse side of the document because the delivered document may not be in the correct sequence of pages with other documents which have been delivered already and it is necessary to put them in correct sequence, which is troublesome.
SUMMARY OF THE INVENTION
The present invention has been devised taking into consideration the situation mentioned above and its object is to simplify the copying treatment for the shortage of copies caused by the copy sheet jamming that takes place during copying the reverse side of a both-side document. To attain the aforesaid object, when a jamming takes place while copying the reverse side of the document, the reverse side of the document is copied on all the copy sheets stored in the intermediate tray, wherein the copy sheets are already copied thereon the obverse side of the document, and then the document is turned over by the automatic document feeding device for the shortage copy sheets caused by the jam and the obverse side of the document is copied on aforesaid shortage copy sheets first and then the document is turned again for the copying of the reverse side thereof.
A further object of the invention is to provide an automatic document feeding device of the document-turnover type wherein the documents are always delivered in the correct sequence of pages when copying a plurality of both-side documents. In order to attain aforesaid object, it is so constituted that when a copying operation is stopped, the documents are to be delivered without taking any action during copying the obverse side of the document and the documents are to be turned and delivered during copying the reverse side of the document, or the documents are to be turned and delivered during copying the obverse side and the documents are delivered without taking an action during copying the reverse side of the document.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a schematic diagram of an electrophotographic copying machine that performs a both-side copying through the method of both-side copying of the invention,
FIG. 2 is a block diagram of a control circuit for the turnover of a document in the electrophotographic copying machine shown in FIG. 1,
FIG. 3 is a flow chart of a copying operation after the occurrence of a jam and
FIG. 4 is a flow chart of a document delivery action of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention will be explained as follows referring to the drawings.
FIG. 1 shows a schematic diagram of an electrophotographic copying machine wherein a both-side copying is performed by the method of both-side copying of the invention and the area A enclosed with a dotted line is an automatic document feeding device of a document-turnover type and the area B is a body of a copying machine for both-side copying. The automatic document feeding device A is composed of document-loading plate 1 on which the documents are stacked, a document-feed-out roller 2 that feeds out only the uppermost document, conveyance belt 4 that conveys the document fed out in cooperation with double-feed-prevention roller 3, rollers 5 for document-feeding arranged along the document-feeding path, transport belt 6 that transports the conveyed document to the prescribed position on the document glass plate, document-turnover guide 7 and three pairs of transport rollers 8a, 8b and 8c, and pressure rollers 6a, 6b and 6c along the transport belt 6 are arranged. This transport belt 6 is driven by driving roller 6d and its movement direction between 6d and 6e is changed to the normal direction shown by an arrow of solid line or to the reverse direction shown by the dotted line arrow. In the vicinity of one end of the transport belt 6, there is provided stopper 9 that stops the transported document to the prescribed position on the document glass plate and this stopper 9 is driven electromagnetically, synchronizing with the feed timing for the document. The first document feeding path beginning from document-loading plate 1 to the fixed position on the document glass plate shares a common path at the section C with the second document feeding path along document-reversing guide 7 and in this common path C, there is provided a document detecting sensor at the passage of the document in which the document detecting sensor consists of light-emitting element 10a and photoreceptor element 10b. The notation 11 represents a document delivery roller that delivers the document which has been exposed, 12 is a document delivery tray accepting the delivered documents and 13 is a document delivery sensor that detects that the document has been delivered.
In this automatic document feeding device of a document-reversing type, each of document-feed-out roller 2, double feed prevention roller 3, conveyance belt 4, document-feeding roller 5, driving roller 6d for transport belt 6 and transport rollers 8a, 8b and 8c arranged along document-reversing guide 7 is driven by a common single document-feeding motor through a clutch or a gear, and among these rollers, driving roller 6d is caused by the change in the rotating direction of a motor to change its rotating direction but other rollers rotate in a one way direction through a reverse rotation mechanism independently of the direction of a motor rotation.
On the other hand, a copying machine body B for both-side-copying employing an electrophotographic process which has been known is provided under aforesaid automatic document feeding device A of a document-reversing type.
The notation 20 is a sheet-feeding cassette on which copy sheets P are stacked and loaded, 21 is feed-out roller that feeds out the uppermost copy sheet P, 22 is a sheet-feeding belt, 23 is a sheet-feed-guide plate, 24 is a sheet-feeding roller and 26 is a revolving drum having thereon a photoreceptor around which are arranged charging unit 27, developing unit 28, transfer unit 29, separating unit 30 and cleaning unit 31.
On the other hand. on the top of the copying machine body, is provided document glass plate 32 on which a document is to be placed at a predetermined position for the exposure and under that, are arranged exposure lamp 33, movable mirrors 34 and 35, fixed mirror 36 and lens 37.
The notation 38 is a transport belt that transports a copied sheet separated from revolving drum 26 after transferring to an image fixing part, 39 is a fixing unit and 40 is a switching device that switches the path for the copied sheet fixed in the fixing unit 39 to delivery path a or to reversing path b and the switching device is composed of 2 pairs of transport rollers 40a and 40b as well as of switching member 40c that rotates in the direction of an arrow around the center of the point E. The notation 41 is a guide plate that guides the sheet copied on its one side toward the intermediate tray, 42 is a transport roller, 43 is a reversing belt that reverses the copied sheet. 43a is a driving roller that drives reversing roller 43, 43b is a driven roller, 44 is an intermediate tray that accepts temporarily the one-side-copied sheets reversed by reversing belt 43, 45 is a true-up plate that moves vertically around a fulcrum F synchronizing with a copying operation and trues up the leading edges of copied sheets contained in intermediate tray 44, 46 is a sheet-feeding roller that moves vertically synchronizing with a copying operation and feeds out the uppermost copied sheet in copied sheets contained in intermediate tray 44, 47 is a sheet-feeding belt, 48 is a transport roller and 49 is a sheet-feeding guide.
Incidentally, 50 is a sheet delivery tray accepting copied sheets delivered after the changeover of switching device 40, 51 is a sheet delivery sensor that is arranged in the vicinity of the copied sheet outlet of the copying machine body B and 52 is an intermediate tray sensor arranged in the vicinity of transport belt 43 and detects the trailng edge of a copy sheet received in intermediate tray 44 after being copied on its one side.
FIG. 2 represents a block diagram of a document-feed-control circuit for conducting the both-side copying of the invention.
In the diagram, 60 is a copy-start button to be turned on when starting copying, 61 is a both-side document button to be turned on when copying a both-side document, 58 is a both-side-copying button to be turned on when copying on both sides of a copy sheet and 59 is a copy-stop button to be turned on when suspending a copy operation or clearing the required number of copied sheets once set. The notation 62 is a setting button for required number of copied sheets to be copied consisting of ten keys with which the number of copied sheets required is set, 10 is a detector for document consisting of light-emitting element 10a and photoreceptor element 10b both shown in FIG. 1, 51 is a sheet delivery sensor appearing also in FIG. 1 and 52 is an intermediate tray sensor. The notation 63 is a memory in which the state of copy-start button 60, both-side document button 61, both-side-copying button 58 and copy-stop button 59, the required number of copied sheets set on setting button and the state of sheet delivery sensor 51 are temporarily stored. 64 is a CPU that judges from the data stored in memory 63 in accordance with predetermined operation program, whether an obverse side of the document is being copied or a reverse side is being copied and whether the copying mode is one-side copying or both-side copying on a copy sheet and thereby outputs the command for reversing or delivering operation for the document and the copy sheet, and 65 is a driving circuit that drives document-feed motor 66 which drives various rollers and driving roller 6d for transport belt 6 through clutches and gears as stated above. Incidentally, copy-start button 60, both-side document button 61, both-side-copying button 58, the copy-stop button, setting button for required number of copied sheets 62, sheet-deliVery sensor 51, memory 63, CPU 64 and driving circuit 65 are all provided on the copying machine side but CPU 64 controls both the document-feeding sequence of the automatic document feeding device and the sequence of the electrophotographic process in the copying machine body.
The both-side copying operation of the invention will be explained next. Incidentally, the following description refers to the occasion wherein image informations printed on both sides of a both-side document are copied on both sides of a copy sheet.
In the ordinary both-side copying operation, a plurality of both-side documents to be copied are placed on document-loading plate 1 in the order of pages with their odd number pages up and both-side document button 61 and both-side-copying button 58 are pressed to made copy mode being both-side-copying mode while setting the required number of copied sheets with setting button for required number of copied sheets 62. Setting is not necessary when the required number is one. CPU 64 confirms the mode of reversing copy sheets and both-side documents for copying through the state wherein both-side document button 61 and both-side-copying button 58 are turned on and after that, when copy-start button 60 is turned on. document-feed motor 66 makes a regular turn and a series of rollers of the automatic document-feeding device rotate. Consequently. the uppermost document on document-loading plate 1 is fed out by document-feed-out roller 2 and transported to transport belt 6 after being fed by conveyance belt 4 and by feed rollers 5. When the leading edge of a dodument passes the position of document-detecting sensor 10 composed of light-emitting element 10a and photoreceptor 10b during the document feeding, the output of photoreceptor 10b rises it's signal level. When stopper 9 has been actuated to be protruded synchronizing with the rise of output signal of document-detecting sensor 10 and when the set time interval t1 on the timer from aforesaid rise of the signal level set in CPU 64 has passed, document-feed motor 66 stops running. At this time, the leading edge of a document hits stopper 9 and is set at the predetermined position on document glass plate 32. At this time, the obverse side corresponding to odd number page side of a document is facing downward in this preferred example. After that, an electrophotographic process starts as a first side copying step.
Namely, the copying machine itself enters into its preparation state for the electrophotographic process, thus revolving drum 26, developing sleeve 28a and heating roller 39a of fixing unit 39 rotate and transport belt 38 starts moving and the heater of heating roller 39a is concurrently energized.
After the prescribed time period, a series of an electrophotographic process beginning with the exposure on document by means of the optical scanning system starts. Thus, the visible image formed on photoreceptor 26 is transferred on copy sheet P fed out from sheet-feeding cassette 20 and then is fixed by fixing unit 39. Slightly before the foregoing, switching member 40c is turned around point A toward the direction of a solid line arrow by unillustrated switching means employing a solenoid and others, corresponding to the state that both-side-copying button is on an ON mode, therefore, a one-side-copied sheet, after fixing, proceeds on reversing path b and is led to guide plate 41 being transported by transport roller 40a and is further transported by transport roller 42 to be put on reversing belt 43. A copied sheet transported by reversing belt 43 is temporarily stored in intermediate tray 44 immediately after being reversed. The similar one-side-copying is performed on copy sheets in the quantity set on setting button for required number of copied sheets and all of them are stored in intermediate tray 44. A one-side-copied sheet to be stored in intermediate tray 44 is detected by intermediate tray sensor 52 immediately before being stored.
CPU 64 counts output signals from intermediate tray sensor 52 and when the counted value becomes equal to the number of copied sheets set by setting button for required number of copied sheets 62, the number is stored in memory 63, CPU 64 judges that the copying mode for obverse side of document is completed and outputs the signal CCW for reverse turning of motor to driving circuit 65, corresponding to the state wherein both-side document button 61 is ON mode. Consequently, document-feed motor 66 makes a reverse turn and the document which has been staying at the predetermined position is transported by transport belt 6 in the direction, directed by dotted line arrow, opposite to that for feeding and thus led to the reversing section. The document is transported through document-reversing-guide 7 by transport rollers 8a, 8b and 8c in the direction of an arrow. The time for reversing operation is counted by the timer incorporated in CPU 64 and when the set time t2 has passed, the output of regular turn signal CW for the motor is made. replacing the signal CCW for reverse turning of motor which has been outputted, thereby the rotation of motor is changed to the regular turn. At this time, the leading edge of the document reversed at the reversing section is in common path C or in its neighborhood and then it further advances and passes the position of document-detecting sensor 10 and reaches transport belt 6 which keeps transporting the document toward the predetermined position for the exposure of document on document glass plate 32. In the same way as the occasion of aforesaid setting of obverse side of document, document-feeding motor 66 stops running when set time t1 on the timer from the rise of output of document-detecting sensor 10 has passed. At this time, the document is staying at the predetermined position on document glass plate 32 being stopped and held by stopper 9 with the reverse side of the document facing downward.
After that, a series of electrophotographic processing as a second side copying step are made for the reverse side of the document. Namely, the exposure on the reverse side of document is made by the optical scanning system, an electrostatic latent image of the reverse side of the document is formed on photoreceptor 26a and it is developed by developing unit 28.
On the other hand, one-side-copied sheets stored in intermediate tray 44 are fed out beginning with the uppermost sheet by sheet-feeding roller 46, synchronizing with the timing of aforesaid electrophotographic process and are transported by sheet-feeding belt 47. A one-side-copied sheet is transported along guide plate 49 by transport-roller 48 and others to the transfer position where a visible image on the reverse side of the document formed on revolving drum 26 is transferred.
Thus, the both-side-copied sheet is transported by transport belt 38 to the fixing position where the both-side-copied sheet is fixed by the fixing unit 39. Since, at this time, switching member 40C of switching device 40 is already switched to the direction of a dotted line direction, the copied sheet to be transported by transport rollers 40a and 40b is delivered from the sheet delivery outlet of the copying machine body through delivery path a and is accepted on sheet delivery tray 50. At this time, the delivery of the copied sheet is detected by sheet delivery sensor 51.
An exposure for the reverse side of a document is made by an optical scanning system in the prescribed timing and at the same time the sheet feeding for one-side-copied sheet is made from intermediate tray 44 synchronizing with a copying operation, thus, the reverse side copying for each copied sheet is made. When the last copied sheet stored in intermediate tray 44 is fed and is delivered after the reverse side copying thereon, CPU 64 judges that the both-side copying has been finished and gives an output of motor-reverse-turn signal CCW to driving circuit 65 because the counted value for the output from sheet delivery sensor 51 agrees with the required number of copied sheets set by setting button for required number of copied sheets 62. Consequently, document-feed motor 66 makes a reverse turn which conveys the copied document to the reversing section where the copied document is reversed and then it is delivered by the regular turn of sheet-feed motor 66 and the output from document delivery sensor 13 causes a next document to be fed.
The foregoing is a normal both-side-copying operation. An operation to be made when a jam takes place during the reverse-side copying related to the present invention will be explained next referring to the flow chart shown in FIG. 3.
Inside copying machine body B, there are arranged a plurarity of sensors along the copy sheet conveyance path. They are hatched squares S 1 ˜S 5 shown in FIG. 1, namely, sensor S 1 provided at the position where a copy sheet fed out from sheet-feeding cassette 20 is advanced after waiting temporarily, sensor S 2 provided at the separation position for the purpose of detecting the copy sheet wound around revolving drum 26, sensor S 4 provided in the vicinity of the entrance to fixing unit 39, sensor S 4 provided on the half way of guide plate 41 in the lower course of switching device 40, aforesaid both sheet delivery sensor 51 and intermediate tray sensor 52, and sensor S 5 provided on the outlet side of intermediate tray 44. Either one of those sensors detects a jam of a copy sheet.
CPU 64 in a copying machine judges, as stated above, whether the machine is in a mode for copying the reverse side of a document or not from the coincidence of a counted value for the output from intermediate tray sensor 52 and the required number of copied sheets set by setting button for required number of copied sheets 62 (F-1). CPU 64 further can judges the copying step being on either the obverse side copying or the reverse side copying from the counted value of the output signal of document-detecting sensor 10. When a jam takes place during the reverse side copying (F-2), the warning for jam occurrence is displayed on the operation section on the top of the copying machine and at the same time, CPU 64 can judge the location of a jam occurrence depending on the specific sensor detecting the jam, thereby can identify the shortage of copied sheets caused by the jam occurrence (f-3). After counter operation for sheet jamming trouble such as by removing jammed sheet and pressing the copy-start button 60 again, the reverse side copying is resumed as a primary copying operation. During this reverse side copying it is judged by CPU 64 that whether the counted value for the output from sheet delivery sensor 51 agrees with the number of sheets which is the required number of copied sheets less the shortage number caused by a jam (F-4) or not. When they agree, it is judged that the reverse side copying mode has been completed, thus, the copying operation for the shortage number is started.
In high-speed copying machines, a plurarity of copy sheets are sometimes in the various steps of electrophotographic process in the copying machine at the same time for the purpose of increasing the copy speed, and all of these copy sheets are sometimes wasted due to the jam occurrence.
Therefore, when copy-start button 60 is pushed again after clearing jammed sheets, one-side-copied sheets remaining in intermediate tray 44 are successively fed out and all of them are subjected to the reverse-side copying as stated above and are delivered in succession.
In this case, sensor S 5 provided at the outlet of intermediate tray sensor 52 detects that no one-side-copied sheet is remaining in intermediate tray 44 and thereby the completion of the reverse-side copying mode is confirmed (F-4) and then from the counted value for the output from sheet-delivery sensor 51 and the set required number of copied sheets, the shortage number of copied sheets caused by jam occurrence may be recognized (F-3). Next, upon completion of the reverse-side copying mode, secondary copying operation described hereinafter is carried out to supplement the shortage number caused by the jam trouble. CPU 64 produces an output of motor-reverse-turn signal CCW, thereby document-feed motor 66 makes a reverse turn, thereby, the document on document glass plate 32 is transported by transport belt 6 and then is reversed by transport rollers 8a, 8b and 8c (F-5). At the stage where the document is mostly reversed, CPU 64 stops producing motor-reverse-turn signal CCW and produces an output of motor-regular-turn signal CW. Consequently, document-feed motor 66 is switched to turn regularly and the direction of a movement of transport belt 6 is changed to that of an arrow of a solid line. When the time period t 1 has passed from the moment when the leading edge of a reversed document passed the position of document-detecting sensor 10, regular-turn signal CW from CPU 64 stops and thereby document-feed motor 66 stops running. At this time. the document is set at the predetermined position on document glass plate 32 with its obverse surface facing downward (F-6). After that, the copying operation for the obverse side of the document is started (F-7). The explanation of aforesaid copying operation will be omitted because it is identical to the operation for aforesaid normal obverse-side copy mode, and the copying is repeated for the number of shortage of copied sheets caused by a jam detected by step (F-3). The copied sheets corresponding to aforesaid shortage in number on which the obverse-side copying is finished (F-8) are stored temporarily in intermediate tray 44. When intermediate tray sensor 52 has detected the last copied sheet of aforesaid shortage number being put in intermediate tray 44, an output of motor-reverse-turn signal CCW is made from CPU 64 and document-feed motor 66 makes a reverse turn. The document-reversing operation thereafter is identical to the occasion of aforesaid normal both-side copying mode (F-9). After document-reversing, when the document is set on document glass plate 32 with its reverse side facing downward (F-10), the reverse-side-copying mode is started. A series of electrophotographic processing is made for the reverse side of a document and the copying is made on each reverse side of documents having their obverse sides copied and stored in intermediate tray 44 (F-11).
After the completion of both-side copying (F-12) for copy sheets corresponding to the shortage number caused by a jam, when a delivery for the last copied sheet is detected by sheet delivery sensor 51, an output of motor-reverse-turn signal CCW is made from CPU 64 and the document on document glass plate 32 is conveyed by transport belt 6 to the reversing section where the document is reversed again (F-13) and passes through the surface of document glass plate 32 again and is delivered (F-14).
As stated above, when a jam takes place during the copying operation for the reverse side of a document in the both-side copying mode wherein copying is made from a both-side document onto both sides of a copy sheet, the document is automatically reversed and both-side copying for the shortage number of copies caused by a jam is made.
In aforesaid example, when a jam takes place during the copying operation for the reverse side of a document, the primary copying operation to made first wherein the reverse side of a document is copied on all of the copied sheets which are copied on their obverse sides and stored in the intermediate tray and the secondary copying operation is made thereafter wherein the document is reversed for the copying of its obverse side as the first side copying step for the shortage number of copy sheets caused by a jam and then the document is reversed again as the second side copying step for the copying of its reverse side, but in the present invention, it is also possible that aforesaid secondary copying operation is made first and the primary copying operation is made later. However, since plural copy sheets, instead of one, tend to be caught by sheet-feed rollers in the intermediate tray after entering the state of sheet-feeding, it is preferable that aforesaid primary copying operation is made first and then the secondary one is made, for the reasons that less trouble is expected when obverse-side-copied sheets remaining in the intermediate tray are fed out quickly and it is convenient for the following operations that the number of both-side-copied sheets is learnt quickly for the calculation of the shortage number.
Next, there will be given an explanation for the occasion wherein a jam occurs while CPU 64 of the copying machine is judging from the counted value for the output from intermediate tray sensor 52 and the number of copies set by setting button for required number of copied sheets 62 that the machine is in the mode of obverse-side copying. In this case, when copy-start button 60 is depressed again after clearing the jam, the reverse-side copying is started, namely, the document is conveyed by transport belt 6 to the reversing section where the document is reversed and then is placed with its reverse side facing downward at the predetermined position on document glass plate 32 for the primary copying operation.
After that, one-side-copied sheets stacked in intermediate tray 44 are fed successively for their reverse-side copying and are delivered, thus the both-side-copied sheets are counted through the output from sheet delivery sensor 51. Sensor S5 provided at the exit of intermediate tray 44 or intermediate tray sensor 52 detects that no one-side-copied sheet is remaining in intermediate tray 44 and the shortage number of copied sheets on that occasion is calculated from the delivered copied sheets and the number of copied sheets set by setting button for required number of copied sheets 62. After that, the document is reversed again for the secondary copying operation so that its obverse side faces downward and then is placed on document glass plate 32 for the both-side copying for the shortage number of copied sheets.
Or, when a jam occurs during the mode of obverse-side copying, the location of the jam is brought to light by the sensor that has detected the jam and the shortage number of copied sheets caused by the jam is calculated as well, thereby, when copy-start button 60 is pushed again after clearing the jam, the obverse-side copying is continued for the shortage number of copied sheets, or the obverse-side copying is carried out until the counted value of intermediate tray sensor 52 becomes identical to the number of copied sheets set by the setting button for required number of copied sheets. After that, it is also possible to deal with the occurrence of a jam during the obverse-side copying by moving to the reverse-side copying after transporting the document to the reversing section and then placing it at the predetermined position on document glass plate 32 with its reverse side facing downward.
Aforesaid example is for the both-side copying, while, when copying on one side of a copy sheet, the state wherein both-side-copying button 58 is in the mode of OFF causes CPU to discriminate that the mode is for the one-side copying. Thereby, switching member 40c swings around point E in the direction of an arrow of a dotted line, which causes copied sheets to be delivered to sheet delivery tray 50 through delivery path a without being conveyed to intermediate tray 44. On the occasion of jam occurrence during the one-side-copying for aforesaid copy sheets, when copy-start button 60 is pushed again after clearing the jam regardless of the copying of the obverse side or the reverse side of the document, the document state at the moment of the jam occurrence is continued and the copying is carried out until the number of copied sheets set by setting button for required number of copied sheets 62 becomes identical to the counted value of the output from sheet delivery sensor 52.
Next, document-delivery actions performed when a copy-stop button 59 is pushed will be explained referring to the flow chart in FIG. 4.
As is shown in FIG. 4, CPU 45 is always discriminating whether copy-stop button 59 is actuated or not (G-1), and when the copy-stop button is being actuated, CPU 45 discriminates whether both-side documents are being copied or not through the state of ON or OFF of both-side document button 61 (G-2). When it is discriminated that both-side documents are not being copied, the documents may be delivered without taking any action because one-side documents are being copied then, but when both-side documents are being copied, it should be discriminated whether the obverse side of a document is being copied or the reverse side thereof is being copied (G-3). This discrimination is made as follows. Namely, the required number of copied sheets is set before copying by setting button for required number of copied sheets 62 and data of the required number of copied sheets is stored in memory 63. Therefore, it is possible to discriminate whether the obverse side of a document is being copied or the reverse side thereof is being copied with the counted value and the data of required number of copied sheets if CPU 64 is counting the output signals from intermediate tray sensor 52 when copying on both sides of a copy sheet, namely, when both-side-copy button 59 is on the mode of ON and if CPU 64 is counting the output signals from sheet delivery sensor 51 when copying only on one side of a copy sheet, namely, when both-side-copy button 59 is on the mode of OFF.
When it is discriminated that the obverse side is being copied, copy-stop-button 59 is actuated to be ON and at the same time, the output of stopper-functioning signal from CPU 64 is discontinued and the output of regular-turn signal CW for the motor is made. As a result, stopper 9 which has been in lifted position until that time gets out of the path and document-feed motor 66 makes a regular turn. Thus, the document is delivered without being reversed (G-4) and document-feed motor 66 is stopped with the timing of the fall of output signals from document-delivery sensor 13.
In contrast with the foregoing, when it is discriminated in step (G-3) that the reverse side of a document is being copied, copy-stop-button 59 is actuated to be ON and at the same time, stopper 9 is caused by the command from CPU 64 to get out of the path and document-feed motor 66 makes a reverse turn. Thereby, transport belt 6 moves in the direction opposite to that for document-feeding, thus, the document is conveyed to the reversing section where the document is reversed (G-5). Document-feed motor 66 is switched to the regular turn after a prescribed period of time and the reversed document is delivered by transport belt 6. The timing of the fall of output signals from document-delivery-sensor 13 stops document-feed motor 66.
As is stated above, a document is delivered without being reversed when the obverse side of the document is being copied, while the document is delivered after being reversed when the reverse side thereof is being copied. Thereby, the obverse side of a document faces downward and the reverse side thereof faces upward, therefore, an order of pages of documents delivered agrees totally with that of documents delivered previously in document-delivery tray 10. In aforesaid example, is illustrated an occasion wherein a copy-stop action was made during the copying operation and it is further possible to deal with similarly the occasion wherein a copy sheet is jammed in a copying machine body. The reason for the foregoing is that it is possible to increase the copying speed for copying on one side of a copy sheet from that for copying on both sides thereof in the invention and in the case of this one-side copying, the document is delivered before the copied sheet finished with an electrophotographic processing thereon is still staying in the copying machine body without being delivered and next document can be fed or set for the purpose of increasing the copying speed. In such a case, when a jam takes place on a copied sheet finished with an electrophotographic processing, the document set in that moment should be delivered temporarily. Further, aforesaid example may be applied to both the occasion for copying a both-side document on one side of a copy sheet and the occasion for copying the same on both sides of a copy sheet. Further, when a document is placed on a document glass plate of an automatic document feeding device, it is also naturally possible to place the document with its even page up. The present invention is not limited to the example stated above but is capable of being applied to various kinds of variations. In the aforesaid example, for instance, when the copying operation is stopped, a document is delivered without being reversed for copying the obverse side of the document, while a document is delivered after being reversed for copying the reverse side of the document, but in contrast with the foregoing, the document may be delivered after being reversed for copying the obverse side of the document, while the document may be delivered without being reversed for copying the reverse side of the document.
Further, in the aforesaid example, a document-reversing section is located at the position that is opposite to the document-delivery side with respect to the document glass plate but the invention is not limited to this and the document-reversing section may naturally be located at the document-delivery side. Further, a document-reversing means may be the so-called switch-back type one instead of above-mentioned means wherein the document is reversed while being transported in the reversing guide by reversing rollers.
In the present invention, as stated above, when a jam takes place while the reverse side of a document is being copied in the both-side copying system wherein an automatic document-feeding device having a document-reversing function is used and both-side copying is made from a both-side document, the first copying process wherein the reverse side of the document is copied on all the copied sheets which are in the intermediate tray and are finished with copying of the obverse side of the document and the second copying process wherein the document is first reversed by the automatic document-feeding device and the obverse side of the document is copied on the shortage number of copied sheets caused by the jam and then the document is reversed again and the reverse side thereof is copied, are carried out. Therefore, the required number of both-side copied sheets are automatically obtained without carrying out the troublesome work such as setting the document manually for the shortage number caused by the jam.
Further, because of the constitution of the invention wherein the document is delivered without being reversed for copying the obverse side of the document when the copying operation is stopped and the document is delivered after being reversed for copying the reverse side of the document, all the documents are always delivered in the same direction and they are in the right order of pages, which is convenient for the following handling. Therefore, it is not necessary to carry out the following work of putting the documents in correct order of pages.
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A method and an apparatus for copying images printed on both sides of a document onto both sides of copy sheets uses an automatic document conveying device capable of reversing the side of a document to be copied. Also disclosed is a the resuming method of a copying operation after removing a jammed sheet during the reverse side copying step of the both-sided document and the delivering method of the both-sided document when the copying operation is cancelled.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 12/626,925 filed on Nov. 29, 2009, which is a continuation-in-part of U.S. patent application Ser. No. 11/646,387 filed on Dec. 28, 2006 now U.S. Pat. No. 7,645,698, which is a continuation of U.S. patent application Ser. No. 10/841,562, filed on May 10, 2004 now U.S. Pat. No. 7,199,040, which is a divisional of U.S. patent application Ser. No. 10/461,346, filed Jun. 16, 2003 now abandoned, all of which are commonly assigned.
BACKGROUND
1. Field of the Invention
The present invention relates to a method for the manufacture of semiconductor devices and more particularly to the method for forming a barrier layer in a damascene structure.
2. Description of the Prior Art
In the processes for the manufacture of semiconductor devices, when the active elements of these semiconductor devices are constructed, the following work will be the manufacture of the metal conductive layers above these active elements to complete the electrical interconnection inside the semiconductor devices. The processes for the manufacture of the metal conductive layers are usually as follows: first, forming a metal layer above the active regions of the semiconductor devices, second, proceeding with photoresist coating, developing, and etching to complete the manufacture of a first metal layer, third, depositing a dielectric layer on the first metal layer, and finally proceeding with the manufacture of multiple metal layers dependent on the needs of the different semiconductor devices.
For many years, materials of metal conductive layers of semiconductors are mainly aluminum and aluminum alloys. However, as sizes of semiconductor devices get more and more smaller, operating speeds of semiconductor devices get more and more faster, and power consumptions of semiconductor devices get more and more lower, it is necessary to use metal materials of lower resistivity and dielectric materials of low dielectric constant to complete the electrical interconnection inside semiconductor devices. U.S. Pat. No. 6,489,240 B1 cites using copper and dielectric materials of dielectric constant lower than 4 to complete the electrical interconnection inside semiconductor devices. When copper is used as the material of metal conductors of semiconductors, as shown in FIG. 1A , considering that copper is difficult to be vaporized after etching processes, a dual damascene structure 10 is often used to proceed with copper forming processes inside the dual damascene structure 10 . U.S. Pat. No. 6,492,270 B1 mentions the details of forming copper dual damascene. A dual damascene structure 10 comprises a first etch-stop layer 120 , a first dielectric layer 160 , a second etch-stop layer 140 , and a second dielectric layer 180 . Before copper processes inside the dual damascene structure 10 above the copper metal layer 100 are performed, as shown in FIG. 1B , a barrier layer 190 has to be formed to prevent copper atoms from diffusing into surrounding dielectric layers.
In order to prevent copper atoms from diffusing into dielectric layers in the prior art, titanium nitride (TiN) or tantalum nitride (TaN) is usually used to form a barrier layer. U.S. Pat. No. 6,541,374 B1 mentions details of forming a barrier layer with TiN. Practically, when the barrier layer 190 is deposited, as a result of the direction of depositing is about perpendicular to the wafer surface, the thickness of the sidewall of the dual damascene structure 10 will be about one-fifth to a half of the thickness above the via bottom in the first dielectric layer 160 and above the trench bottom in the second dielectric layer 180 , easily causing that the deposition of the sidewall of the dual damascene structure 10 is incomplete and copper atoms formed later in the dual damascene structure 10 diffuse into surrounding dielectric layers. Consequently the electric property of the surrounding dielectric layers will be affected and then the semiconductor devices will be damaged. Accordingly there is a need for completely depositing a barrier layer of the sidewall of a dual damascene structure 10 to prevent copper atoms from diffusing into surrounding dielectric layers.
In the other hand, the resistivity of nitrided metal materials in the prior art is far more higher than the resistivity of metal materials. Hence if TiN or TaN is used as the material of the barrier layer 190 in the dual damascene structure 10 , the resistivity between metals in the dual damascene structure 10 will be so high that the operating speed and the power consumption of the semiconductor devices will be influenced. Therefore there is a need for reducing the resistivity of the barrier layer 190 above the via bottom in the first dielectric layer 160 .
BRIEF SUMMARY
One main purpose of the present invention is to use the barrier layer formed by at least two metal layers and a barrier layer of metallized materials to fully prevent copper atoms from diffusing into surrounding dielectric layers.
The other main purpose of the present invention is to reduce the resistivity of the barrier layer above the via bottom in the dielectric layer of a dual damascene structure and to make a good ohmic contact between the barrier layer and the copper layer below the barrier layer and the copper layer later formed above the barrier layer.
In one embodiment, a damascene structure is disclosed. The damascene structure includes a conductive layer, a first dielectric layer, a first barrier metal layer, a barrier layer, a second barrier metal layer and a third barrier metal layer. The first dielectric layer is disposed on the conductive layer, and has a via therein. The first barrier metal layer is disposed on the via bottom and the via sidewall in the first dielectric layer. The first barrier metal layer covers the conductive layer on the via bottom. The barrier layer is comprised of a material different with that of the first barrier metal layer. The second barrier metal layer covers the barrier layer on the via sidewall, and exposes the barrier layer on the via bottom. The third barrier metal layer covers the second barrier metal layer on the via sidewall, and covers the first barrier metal layer on the via bottom. A bottom of the barrier layer disposed on the via bottom is not punched through.
The present invention uses chemical vapor deposition processes or physical vapor deposition processes to form a barrier layer on a conductive layer of a semiconductor device and then uses ion-bombardment to remove metallized materials of higher resistivity to reduce the resistivity of the barrier layer neighboring to the conductive layer.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which:
FIG. 1A shows an illustrative chart of a dual damascene structure of the prior art;
FIG. 1B shows an illustrative chart of forming a barrier layer on a dual damascene structure of the prior art;
FIGS. 2A-2E shows an illustrative chart of the steps for forming multi-barrier layers on a dual damascene structure of a first embodiment in the present invention;
FIGS. 3A-3E shows an illustrative chart of the steps for forming multi-barrier layers on a damascene structure of a second embodiment in the present invention;
FIG. 4 shows an illustrative chart of proceeding with physical vapor deposition processes in a plasma reactor in the present invention;
FIG. 5 shows an illustrative chart of proceeding with ion-bombardment processes in a plasma reactor in the present invention;
FIGS. 6D-6E shows an illustrative chart of the steps for forming multi-barrier layers on a dual damascene structure of a third embodiment in the present invention;
FIGS. 7D-7E shows an illustrative chart of the steps for forming multi-barrier layers on a damascene structure of a fourth embodiment in the present invention;
FIGS. 8B-8E shows an illustrative chart of the steps for forming multi-barrier layers on a dual damascene structure of a fifth embodiment in the present invention;
FIGS. 9B-9E shows an illustrative chart of the steps for forming multi-barrier layers on a damascene structure of a sixth embodiment in the present invention;
FIG. 10E shows an illustrative chart of forming multi-barrier layers on a dual damascene structure of a seventh embodiment in the present invention; and
FIG. 11E shows an illustrative chart of forming multi-barrier layers on a damascene structure of an eighth embodiment in the present invention.
DETAILED DESCRIPTION
Some embodiments of the invention will be described exquisitely as below. Besides, the invention can also be practiced extensively in other embodiments. That is to say, the scope of the invention should not be restricted by the proposed embodiments. The scope of the invention should be based on the claims proposed later.
In a first embodiment of the present invention, as shown in FIGS. 2A-2E , a dual damascene structure 20 has been already formed on a metal layer 200 of a wafer. The dual damascene structure 20 comprises a first etch-stop layer 220 , a first dielectric layer 260 on the first etch-stop layer 220 , a second etch-stop layer 240 on the first dielectric layer 260 , and a second dielectric layer 280 on the second etch-stop layer 240 , wherein the metal layer 200 is a copper layer. A material of the first etch-stop layer 220 and the second etch-stop layer 240 is the one which can prevent copper atoms from diffusing into surrounding dielectric layers, such as silicon nitride (Si.sub.3N.sub.4). The material of the first dielectric layer 260 and the second dielectric layer 280 can be silicon dioxide or any other material whose dielectric constant is lower than 4, such as fluorinated silicate glass (FSG), organo silicate glass, fluorinated amorphous carbon, hydrogenated amorphous carbon, and tetrafluoropoly-p-xylylene. The first dielectric layer 260 and the second dielectric layer 280 of these materials can be formed by chemical vapor deposition processes. The material of the first dielectric layer 260 and the second dielectric layer 280 can also be hydrogenated silsesquioxane (HSQ), poly arylene ethers (PAE), co-polymer of divinylsiloxane and bis-Benzocyclobutene, aerogel, and xerogel. The first dielectric layer 260 and the second dielectric layer 280 can be formed by spin coating.
As shown in FIG. 2A , a first tantalum layer 300 is formed on the dual damascene structure 20 and the first tantalum layer 300 can be formed by chemical vapor deposition (CVD) processes or physical vapor deposition (PVD) processes. The first tantalum layer 300 is formed by PVD processes in the present embodiment. A plasma reactor 60 is shown in FIG. 4 , a wafer 62 is secured to a wafer supporter 61 and the wafer supporter 61 is connected to a direct current (DC) bias 65 . A tantalum target 64 is secured to a metal target base 63 and the metal target base 63 is grounded. In the PVD processes, argon ions will bombard the tantalum target 64 and the tantalum atoms or ions bombarded out by argon ions will be attracted by the DC bias 65 and deposited on the wafer 62 thereby forming the first tantalum layer 300 . In the PVD processes, the process pressure in the plasma reactor 60 is about from 0 torrs to 50 millitorrs and the process temperature in the plasma reactor 60 is about from 0 degrees centigrade to 400 degrees centigrade.
As shown in FIG. 2B , a tantalum nitride layer 320 is formed on the first tantalum layer 300 and the tantalum nitride layer 320 can be formed by CVD processes or PVD processes. The tantalum nitride layer 320 is formed by PVD processes in the present embodiment. Similar to the way of forming the first tantalum layer 300 , nitrogen gas is introduced into the plasma reactor 60 and the nitrogen molecules will react with the tantalum atoms 67 or tantalum ions 66 from the tantalum target 64 , which is bombarded by argon ions to form the tantalum nitride layer 320 on the wafer 62 . In the PVD processes, the process pressure in the plasma reactor 60 is about from 0 torrs to 50 millitorrs and the process temperature in the plasma reactor 60 is about from 0 degrees centigrade to 400 degrees centigrade.
The resistivity of the tantalum nitride layer 320 varies with the proportion of the nitrogen atoms. Generally, the resistivity of the tantalum nitride layer 320 is about between 95 micro-ohms centimeter and 14800 micro-ohms centimeter. The resistivity of the tantalum nitride layer 320 is far more than the resistivity of a tantalum layer. The resistivity of an α-phase tantalum layer is about between 15 micro-ohms centimeter and 30 micro-ohms centimeter and the resistivity of a β-phase tantalum layer is about between 150 micro-ohms centimeter and 220 micro-ohms centimeter. However, the resistivity of a copper layer is about 1.7 micro-ohms centimeter. Accordingly, in order to reduce the resistivity above the via bottom in the first dielectric layer 260 , the tantalum nitride layer 320 above the via bottom in the first dielectric layer 260 has to be removed.
As shown in FIG. 2C , in order to remove the tantalum nitride layer 320 above the via bottom in the first dielectric layer 260 , a method of ion-bombardment is taken. As shown in FIG. 5 , a plasma reactor 80 is connected with a plasma generating power 84 and an alternating current bias power 83 . A wafer 82 is secured to a wafer supporter 81 in the plasma reactor 80 . When an ion-bombardment process is proceeded with, a self-direct current bias produced by the alternating current bias power 83 attracts argon ions 86 in the plasma 85 to bombard the wafer 82 . Then the tantalum atoms 360 , which escape from the tantalum nitride layer 320 above the via bottom in the first dielectric layer 260 , will be deposited on the via sidewall in the first dielectric layer 260 . The tantalum nitride layer 320 above the via bottom in the first dielectric layer 260 is removed. Because a moving direction of the argon atoms 86 is perpendicular to a surface of the wafer 82 , the tantalum nitride layer 320 deposited on the via sidewall in the first dielectric layer 260 sustains less ion-bombardment than the tantalum nitride layer 320 deposited above the via bottom in the first dielectric layer 260 . In the present embodiment, the self-direct current bias produced on the wafer supporter 81 is higher than the direct current bias in the PVD processes for deposition of the tantalum layer or the tantalum nitride layer.
After the tantalum nitride layer 320 above the via bottom in the first dielectric layer 260 is removed by the method of ion-bombardment, the structure above the metal layer 200 is shown in FIG. 2D . Only the first tantalum layer 300 exists above the via bottom in the first dielectric layer 260 . The tantalum atoms 360 sputtered from the via bottom in the first dielectric layer 260 and from the trench bottom in the second dielectric layer 280 will then separately be deposited on the sidewall of the downside of the via in the first dielectric layer 260 and on the sidewall of the downside of the trench in the second dielectric layer 280 . The figure of the structure is shown in FIG. 2D . Further, as shown in FIG. 2E , a second tantalum layer 340 is formed on the tantalum nitride layer 320 by the method such as the aforementioned method used for forming the first tantalum layer 300 . The second tantalum layer 340 can be formed by PVD processes or CVD processes. The second tantalum layer 340 is formed by PVD processes in the embodiment. A plasma reactor 60 is shown in FIG. 4 , a wafer 62 is secured to a wafer supporter 61 and the wafer supporter 61 is connected to a direct current (DC) bias 65 . A tantalum target 64 is secured to a metal target base 63 and the metal target base 63 is grounded. In the PVD processes, argon ions will bombard the tantalum target 64 and the tantalum atoms or ions bombarded out by argon ions will be attracted by the DC bias 65 to be deposited on the wafer 62 thereby forming the second tantalum layer 340 . In the PVD processes, the process pressure in the plasma reactor 60 is about from 0 torr to 50 millitorrs and the process temperature in the plasma reactor 60 is about from 0 degrees centigrade to 400 degrees centigrade.
After completing the aforementioned steps, the barrier layers of the dual damascene structure 20 are shown in FIG. 2E . Only the tantalum layer, which consists of the first tantalum layer 300 and the second tantalum layer 340 , exists above the via bottom in the first dielectric layer 260 of the dual damascene structure 20 , however, all the three barrier layers exist on all the other portions of the dual damascene structure 20 except the via bottom. The three barrier layers are the first tantalum layer 300 , the tantalum nitride layer 320 , and the second tantalum layer 340 respectively. The tantalum is used because it has good adhesion to copper. The tantalum nitride is capable of preventing copper atoms from diffusing into surrounding dielectric layers. The barrier structure of the three barrier layers is thicker than the barrier layer at the side wall portion of a dual damascene structure in the prior art and thus the three barrier layers prevent copper atoms from diffusing into surrounding dielectric layers more efficiently. Besides, a portion of the barrier layer structure above the via bottom has a 30% lower resistance than of the prior art. Therefore, the tantalum layer has better ohmic contact with the copper layer below and the copper layer formed inside the dual damascene structure later.
In another embodiment of the present disclosure, as shown in FIGS. 3A-3E , a damascene structure 40 has been already formed on a metal layer 400 of a wafer. The damascene structure 40 comprises an etch-stop layer 420 and a dielectric layer 440 on the etch-stop layer 420 . The metal layer 400 is a copper layer. The etch-stop layer 420 consists of a material which can prevent copper atoms from diffusing into surrounding dielectric layers such as silicon nitride (Si.sub.3N.sub.4). The material of the dielectric layer 440 can be silicon dioxide or any other material whose dielectric constant is lower than 4, such as fluorinated silicate glass (FSG), organo silicate glass, fluorinated amorphous carbon, hydrogenated amorphous carbon, and tetrafluoropoly-p-xylylene. The dielectric layer 440 of these materials can be formed by chemical vapor deposition processes. The material of the dielectric layer 440 can also be hydrogenated silsesquioxane (HSQ), poly arylene ethers (PAE), co-polymar of divinylsiloxane and bis-Benzocyclobutene, aerogel, and xerogel, and dielectric layer 440 of these materials can be formed by spin coating.
As shown in FIG. 3A , a first tantalum layer 460 is formed on the damascene structure 40 and the first tantalum layer 460 can be formed by chemical vapor deposition (CVD) processes or physical vapor deposition (PVD) processes. The first tantalum layer 460 is formed by PVD processes in the present embodiment. A plasma reactor 60 is shown in FIG. 4 , a wafer 62 is secured to a wafer supporter 61 and the wafer supporter 61 is connected to a direct current (DC) bias 65 . A tantalum target 64 is secured to a metal target base 63 and the metal target base 63 is grounded. In the PVD processes, argon ions will bombard the tantalum target 64 and the tantalum atoms or ions bombarded out by the argon ions will be attracted by the DC bias 65 to be deposited on the wafer 62 thereby forming the first tantalum layer 460 . In the PVD processes, the process pressure in the plasma reactor 60 is about from 0 torr tos 50 millitorrs and the process temperature in the plasma reactor 60 is about from 0 degrees centigrade to 400 degrees centigrade.
As shown in FIG. 3B , a tantalum nitride layer 480 is formed on the first tantalum layer 460 and the tantalum nitride layer 480 can be formed by CVD processes or PVD processes. The tantalum nitride layer 480 is formed by PVD processes in the present embodiment. Similar to the way of forming the first tantalum layer 460 , nitrogen gas is introduced into the plasma reactor 60 and the nitrogen molecules will react with the tantalum atoms 67 or tantalum ions 66 from the tantalum target 64 to form the tantalum nitride layer 480 . In the PVD processes, the process pressure in the plasma reactor 60 is about from 0 torrs to 50 millitorrs and the process temperature in the plasma reactor 60 is about from 0 degrees centigrade to 400 degrees centigrade.
The resistivity of the tantalum nitride layer 480 varies with the proportion of the nitrogen atoms. Generally, the resistivity is about between 95 micro-ohms centimeter and 14800 micro-ohms centimeter. The resistivity of the tantalum nitride layer 480 is far more than the resistivity of a tantalum layer. The resistivity of the α-phase tantalum layer is about between 15 micro-ohms centimeter and 30 micro-ohms centimeter and the resistivity of the β-phase tantalum layer is about between 150 micro-ohms centimeter and 220 micro-ohms centimeter. However, the resistivity of a copper layer is about 1.7 micro-ohms centimeter. Accordingly, to reduce the resistivity above the via bottom in the dielectric layer 440 , the tantalum nitride layer 480 above the via bottom in the dielectric layer 440 has to be removed.
As shown in FIG. 3C , in order to remove the tantalum nitride layer 480 above the via bottom in the dielectric layer 440 , a method of ion-bombardment is taken. As shown in FIG. 5 , a plasma reactor 80 is connected with a plasma generating power 84 and an alternating current bias power 83 . A wafer 82 is secured to a wafer supporter 81 in the plasma reactor 80 . When an ion-bombardment process is proceeded with, a self-direct current bias produced by the alternating current bias power 83 attracts argon ions 86 in the plasma 85 to bombard the wafer 82 , and then tantalum atoms 520 , which escape from the tantalum nitride layer 480 above the via bottom in the dielectric layer 440 , will be deposited on the via sidewall in the dielectric layer 440 . The tantalum nitride layer 480 above the via bottom in the dielectric layer 440 is removed. Because a moving direction of the argon atoms 86 is perpendicular to a surface of the wafer 82 , the tantalum nitride layer 480 deposited on the via sidewall in the dielectric layer 440 sustains less ion-bombardment than the tantalum nitride layer 480 deposited above the via bottom in the dielectric layer 440 . In the present embodiment, the self-direct current bias produced on the wafer supporter 81 is higher than the direct current bias in the PVD processes for deposition of the tantalum layer or the tantalum nitride layer.
After the tantalum nitride layer 480 above the via bottom in the dielectric layer 440 is removed by the method of ion-bombardment, the structure above the metal layer 400 is shown in FIG. 3D . Only the first tantalum layer 460 exists above the via bottom in the dielectric layer 440 . The tantalum atoms 520 that escape from the via bottom in the dielectric layer 440 is deposited on the sidewall of the downside of the via in the dielectric layer 440 . Then, the figure of the structure is shown in FIG. 3D . Further, as shown in FIG. 3E , a second tantalum layer 500 is formed on the tantalum nitride layer 480 by a method such as the aforementioned method used for forming the first tantalum layer 460 . The second tantalum layer 500 can be formed by PVD processes or CVD processes. The second tantalum layer 500 is formed by PVD processes in the present embodiment. A plasma reactor 60 is shown in FIG. 4 , the wafer 62 is secured to the wafer supporter 61 and the wafer supporter 61 is connected to the direct current (DC) bias 65 . The tantalum target 64 is secured to the metal target base 63 and the metal target base 63 is grounded. In the PVD processes, argon ions will bombard the tantalum target 64 and the tantalum atoms or ions will be attracted by the DC bias 65 to be deposited on the wafer 62 thereby forming the second tantalum layer 500 . In the PVD processes, the process pressure in the plasma reactor 60 is about from 0 torrs to 50 millitorrs and the process temperature in the plasma reactor 60 is about from 0 degrees centigrade to 400 degrees centigrade.
After completing the aforementioned steps, the barrier layers of the damascene structure 40 are shown in FIG. 3E . Only the tantalum layer consisting of the first tantalum layer 460 and the second tantalum layer 500 exists above the via bottom in the dielectric layer 440 of the damascene structure 40 , however the three barrier layers exist on all the other portions of the damascene structure 40 except the via bottom. The three barrier layers are the first tantalum layer 440 , the tantalum nitride layer 480 , and the second tantalum layer 500 respectively. The tantalum is used because it has good adhesion to copper. The tantalum nitride is capable of preventing copper atoms from diffusing into surrounding dielectric layers. The barrier structure of the three barrier layers is thicker than the barrier layer of the side wall portion of a dual damascene structure in the prior art, and thus the barrier structure prevent copper atoms from diffusing into surrounding dielectric layers more efficiently. Besides, the portions of the tantalum layers directly above the via bottom of the dielectric layer has 30% lower resistance than that of the prior art. Therefore, the tantalum layer will have better ohmic contact with the copper layer below and the copper layer formed inside the damascene structure later.
It is noted that the barrier layer of metallized materials disposed on the via bottom may be punched through in the above-mentioned embodiments, and may just be thinned in other embodiments. FIGS. 6D-6E illustrate a method for forming multi-barrier layers on a dual damascene structure of a third embodiment in the present disclosure. Compared with the first embodiment discussed previously, same labels will be carried forward through FIGS. 6D-6E .
As shown in FIG. 6D , a dual damascene structure 70 is formed on the metal layer 200 of a wafer, the first tantalum layer 300 is formed on the dual damascene structure 70 , a tantalum nitride layer 320 a is formed on the first tantalum layer 300 , and an ion-bombardment process may be performed on the tantalum nitride layer 320 a through the steps shown in FIG. 2A-2C . One difference between the first embodiment and the third embodiment is that the ion-bombardment process does not punch through the tantalum nitride layer 320 a disposed on the via bottom in the third embodiment. In other words, only portions of the tantalum nitride layer 320 a on the via bottom in the first dielectric layer 260 are removed. Portions of the tantalum nitride layer 320 a may still remain on the via bottom and the via sidewall in the first dielectric layer 260 without removing the first tantalum layer 300 on the via bottom. In the ion-bombardment process, a self-direct current bias attracts argon ions 86 to bombard the tantalum nitride layer 320 a , and the tantalum atoms 360 that escape from the tantalum nitride layer 320 on the via bottom move toward the via sidewall. Therefore, the tantalum nitride layer 320 a may still remain on the whole via bottom in the first dielectric layer 260 , and portions of the tantalum nitride layer 320 a disposed on the via bottom is thinned by the ion-bombardment process.
As shown in FIG. 6E , the second tantalum layer 340 is formed on the tantalum nitride layer 320 a . After completing the aforementioned steps, the tri-layer barrier structure including the first tantalum layer 300 , the tantalum nitride layer 320 a and the second tantalum layer 340 may be disposed on both the via bottom and the whole via sidewall. Portions of the tantalum nitride layer 320 a disposed on the via bottom may be thinner than portions of the tantalum nitride layer 320 a disposed on the via sidewall. After the second tantalum layer 340 is formed, a conductive layer, such as copper layer, (not shown) may be formed on the second tantalum layer 340 and filling the dual damascene structure 70 . Since the resistivity of the tantalum nitride layer 320 a varies with the proportion of the nitrogen atoms within the tantalum nitride layer 320 a , and the tantalum nitride layer 320 a may be thinned, the resistance above the via bottom in the first dielectric layer 260 can also be effectively reduced.
The ion-bombardment process without punching through the tantalum nitride layer may also be applied to a damascene structure. FIGS. 7D-7E , a method for forming multi-barrier layers on a damascene structure of a fourth embodiment in the present disclosure is illustrated. In order to compare to the second embodiment discussed previously, same labels will be carried forward through FIGS. 7D-7E .
As shown in FIG. 7D , a damascene structure 90 is formed on a metal layer 400 of a wafer, the first tantalum layer 460 is formed on the dual damascene structure 90 , the tantalum nitride layer 480 a is formed on the first tantalum layer 460 , and an ion-bombardment process may be performed on the tantalum nitride layer 480 a through the steps shown in FIG. 3A-3C . One difference between the second embodiment and the fourth embodiment is that the ion-bombardment process does not punch through the tantalum nitride layer 480 a disposed on the via bottom in the fourth embodiment. In other words, only portions of the tantalum nitride layer 480 a on the via bottom in the dielectric layer 440 are removed. Portions of the tantalum nitride layer 480 a may still remain on the whole bottom and the whole via sidewall in the dielectric layer 440 without removing the first tantalum layer 460 on the via bottom.
As shown in FIG. 7E , the second tantalum layer 500 is formed on the tantalum nitride layer 480 a . After completing the aforementioned steps, the tri-layer barrier structure including the first tantalum layer 300 , the tantalum nitride layer 480 a and the second tantalum layer 500 may be disposed on both the via bottom and the whole via sidewall. Portions of the tantalum nitride layer 480 a disposed on the via bottom may be thinner than portions of the tantalum nitride layer 480 a disposed on the via sidewall. Since the resistivity of the tantalum nitride layer 480 a varies with the proportion of the nitrogen atoms within the tantalum nitride layer 480 a , and the tantalum nitride layer 480 a may be thinned, the resistance above the via bottom in the dielectric layer 440 can also be effectively reduced.
Moreover, the multi-barrier layers formed on the damascene structure or on the dual damascene structure may include more than three barrier layers in other embodiments. Please refer to FIGS. 8B-8E , a method for forming multi-barrier layers on a dual damascene structure of a fifth embodiment in the present invention is illustrated. In order to compare to the first embodiment discussed previously, same labels will be carried forward through FIGS. 8B-8E .
As shown in FIG. 8B , a dual damascene structure 30 is first formed on the metal layer 200 of a wafer, the first tantalum layer 300 is formed on the damascene structure 50 , and the tantalum nitride layer 320 is formed on the first tantalum layer 300 through the steps shown in FIG. 2A-2B . One difference between the first embodiment and the fifth embodiment is that a second tantalum layer 340 is further formed on the tantalum nitride layer 320 before the ion-bombardment process in the fifth embodiment.
As shown in FIG. 8C-8D , an ion-bombardment process may be performed next on both the second tantalum layer 340 and the tantalum nitride layer 320 . The ion-bombardment process may first remove the second tantalum layer 340 , and may subsequently remove the tantalum nitride layer 320 after the second tantalum layer 340 is punched through. In this embodiment, the ion-bombardment process may punch through both the second tantalum layer 340 and the tantalum nitride layer 320 disposed on the via bottom. Only the first tantalum layer 300 exists above the via bottom in the first dielectric layer 260 . The ion-bombardment process may leave the second tantalum layer 340 and the tantalum nitride layer 320 remaining on the whole via sidewall in the first dielectric layer 260 without removing the first tantalum layer 300 on the via bottom.
As shown in FIG. 8E , the third tantalum layer 350 is formed on the second tantalum layer 340 and the tantalum nitride layer 320 . After completing the aforementioned steps, both the first tantalum layer 300 and the third tantalum layer 350 may be disposed on the via bottom; and the first tantalum layer 300 , the tantalum nitride layer 320 , the second tantalum layer 340 and the third tantalum layer 350 may be disposed on the whole via sidewall. In other words, there are four barrier layers, which include the first tantalum layer 300 , the tantalum nitride layer 320 , the second tantalum layer 340 and the third tantalum layer 350 , on the via sidewall to prevent copper atoms from diffusing into surrounding dielectric layers. Portions of the tantalum nitride layer 320 disposed on the via bottom is punched through or thinned. After the third tantalum layer 350 is formed, a conductive layer, such as copper layer, (not shown) may be formed on the third tantalum layer 350 and filling the dual damascene structure 30 . Since the resistivity of the tantalum nitride layer 320 varies with the proportion of the nitrogen atoms within the tantalum nitride layer 320 , and the tantalum nitride layer 320 may be punched through or thinned, the resistance above the via bottom in the first dielectric layer 260 can also be effectively reduced.
It can be understood that portions of the tantalum nitride layer 320 and/or portions of the second tantalum layer 340 may still remain on the via bottom in other embodiments, as shown in FIG. 10E .
The four-barrier layers may also be applied to a damascene structure. Please refer to FIGS. 9B-9E , a method for forming multi-barrier layers on a damascene structure of a sixth embodiment in the present invention is illustrated. In order to compare to the second embodiment discussed previously, same labels will be carried forward through FIGS. 9B-9E .
As shown in FIG. 9B , a damascene structure 50 is first formed on a metal layer 400 of a wafer, the first tantalum layer 460 is formed on the damascene structure 50 , and the tantalum nitride layer 480 is formed on the first tantalum layer 460 through the steps shown in FIG. 3A-3B . One difference between the second embodiment and the sixth embodiment is that the second tantalum layer 500 is further formed on the tantalum nitride layer 480 before the ion-bombardment process in the sixth embodiment.
As shown in FIG. 9C-9D , an ion-bombardment process may be performed on both the second tantalum layer 500 and the tantalum nitride layer 480 on the via bottom. The ion-bombardment process may first remove the second tantalum layer 500 , and may subsequently remove the tantalum nitride layer 480 . In this embodiment, the ion-bombardment process may punch through both the second tantalum layer 500 and the tantalum nitride layer 480 disposed on the via bottom. The ion-bombardment process may leave both the second tantalum layer 500 and the tantalum nitride layer 480 remaining on the whole via sidewall in the dielectric layer 440 without removing the first tantalum layer 460 on the via bottom.
As shown in FIG. 9E , the third tantalum layer 510 is formed on the second tantalum layer 500 and the tantalum nitride layer 480 . After completing the aforementioned steps, the first tantalum layer 460 and the third tantalum layer 510 may be disposed on the via bottom; and the first tantalum layer 460 , the tantalum nitride layer 480 , the second tantalum layer 500 and the third tantalum layer 510 may be disposed on the whole via sidewall. In other words, there are four barrier layers, which include the first tantalum layer 460 , the tantalum nitride layer 480 , the second tantalum layer 500 and the third tantalum layer 510 , on the via sidewall to prevent copper atoms from diffusing into surrounding dielectric layers. Portions of the tantalum nitride layer 480 disposed on the via bottom is punched through or thinned. Since the resistivity of the tantalum nitride layer 480 varies with the proportion of the nitrogen atoms within the tantalum nitride layer 480 , and the tantalum nitride layer 480 may be punched through or thinned, the resistance above the via bottom in the dielectric layer 440 can also be effectively reduced.
It can be understood that portions of the second tantalum layer 500 and portions of the tantalum nitride layer 480 may still remain on the via bottom in other embodiments, as shown in FIG. 11E .
The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein, including configurations ways of the recessed portions and materials and/or designs of the attaching structures. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments. As with the operating sequence of the present invention, many variations are possible, and any rearrangement of the operating sequence for achieving same functionality is still within the spirit and scope of the invention.
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A damascene structure includes a conductive layer, a first dielectric layer, a first barrier metal layer, a barrier layer, and a second barrier metal layer sequentially formed on the conductive layer. The first dielectric layer having a via therein. The barrier layer is comprised of a material different with that of the first barrier metal layer. A bottom of the barrier layer disposed on the via bottom is not punched through. The accomplished barrier layers will have lower resistivity on the via bottom in the first dielectric layer and they are capable of preventing copper atoms from diffusing into the dielectric layer.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit and priority of Korean Patent Application No. 10-2012-0081305 filed Jul. 25, 2012. The entire disclosure of the above application is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present invention relates to an energetic reactive plasticizer for a plastic bonded explosive, and specifically to an energetic reactive plasticizer for a plastic bonded explosive which has high performance and insensitiveness without a migration problem of a plasticizer by being bonded with a polymer binder for a plastic bonded explosive.
BACKGROUND ART
[0003] Currently, efforts to make energetic materials insensitive have been a significant issue in development of explosives and a propellant. As a part of such efforts, plastic bonded explosives (PBXs) having low sensitivity and improved mechanical properties while maintaining high energy properties have been developed. Such PBX now becomes an elementary component of high-energy explosives, polymeric binders and other additives used in a small amount such as a plasticizer or a stabilizer.
[0004] Currently, a polyurethane polymeric binder on the basis of a hydroxyl-terminated polybutadiene (HTPB) has been used as a widely applicable polymeric binder system, together with various additives so as to improve processability, mechanical properties and chemical stability. Although such polymeric binder shows excellent properties in making high-energy materials insensitive, it has been proposed that it generally disadvantageously reduces the energy density of PBX on the whole owing to its low energy potential. In this regard, many studies have been being made to increase the whole energy density through development of energetic binders and plasticizers containing energetic functional groups such as, for example, nitro (C—NO 2 ), nitrate (O—NO 2 ), nitramine (N—NO 2 ), azido (—N 3 ) and difluoroamino (—NF 2 ) and application thereof.
[0005] The term “energetic functional groups” as used herein has common and general meaning as used in the field of molecular explosives, i.e, referring to functional groups, when being applied to a molecular explosive or a plasticizer, known to contribute to the increase in the whole energy level of PBX to which the explosive or plasticizer were applied. Nitro (C—NO 2 ), nitrate (O—NO 2 ), nitramine (N—NO 2 ), azido (—N 3 ), difluoroamino (—NF 2 ) or the like as described above may be mentioned. The term “energetic” as used herein means that the whole energy level of a molecular explosive is more increased by any known methods comprising the introduction of such “energetic” functional groups.
[0006] However, those polymeric binders and plasticizers which comprise such energetic functional groups have problems such as low heat stability, non-compatibility with explosives and low processability. Therefore, it has been an important rising issue to ultimately achieve both high performance and insensitiveness in explosives. Further, when an energetic plasticizer is applied, an additional problem such as a migration of the energetic plasticizer from PBX occurs over a long period of time. Such migration of an energetic plasticizer involves further additional problems in PBX such as increase in sensitivity to impact and decrease in storage stability and long-term stability owing to deterioration in mechanical properties. Therefore, the realization of an explosive having both high performance and insensitiveness still has been an important matter to be achieved in this field of art.
[0007] When a highly energetic polymer which can satisfy both high performance and insensitiveness at the same time is prepared, it is anticipated to obtain a novel energy material which is combined with a molecular explosive and a binder and has an excellent performance and safety.
SUMMARY OF THE INVENTION
[0008] The present invention is to provide an energetic reactive plasticizer which can satisfy the high performance and insensitiveness required in the next-generation explosives without a plasticizer migration and thereby preventing various problems accompanied with such migration.
DETAILED DESCRIPTION OF THE INVENTION
[0009] PBX is majorly composed of a molecular explosive and a prepolymer and a curing agent for the formation of a binder, and additionally comprises other additives such as a plasticizer on necessary. All the components are introduced, mixed together and then loaded into a container for an explosive, this procedure of which is called a casting process. The prepolymer and the curing agent react in the container to form a binder while solidifying the components in the container.
[0010] The ‘reactive plasticizer’ is a high energy alkyne compound having low viscosity, which can be served as a plasticizer during mixing of PBX and attached to a polymer in a casting or curing process as above. The reactive plasticizer acts as a plasticizer in the preparation of PBX, and a part of or the whole plasticizer is bound into a binder by click reaction by itself in a curing process of the final preparation process.
[0011] The present inventors have found that by using a reactive plasticizer in a way of introducing high energy prepolymers in PBX preparation process, it acts as a plasticizer during the casting process, thereby solving the conventional viscosity problem and further it binds to a binder during a curing process, thereby reducing bleeding or migration of a plasticizer, and thus completed the present invention.
[0012] In other words, the present invention provides a novel reactive plasticizer having high energy potential by comprising a high energy functional group as well as a functional group which can react with a corresponding energetic prepolymer/a curing agent during a curing process in the preparation of a binder for PBX, thereby being bound to the high energy polymer binder as a side chain thereof.
[0013] The energetic reactive plasticizer according to the present invention binds with a side chain of a binder via a click reaction between azide and acetylene groups during the curing process. For such reaction, the energetic reactive plasticizer of the present invention comprises acetylene functional groups and the bond between the energetic functional group and the reactive functional group is an ester bond. In this regard, the novel energetic reactive plasticizer according to the present invention may be classified as an ester-based reactive plasticizer having high energy potential, considering the type of bond characteristically formed in the backbone of the compound is an ester bond.
[0014] The ester-based energetic reactive plasticizer is an ester-based compound obtained according to the following reaction scheme 1:
[0000]
[0015] (wherein, n=a natural number selected from 1-10).
[0016] As seen from the above reaction scheme 1, the reactive energetic plasticizer containing ester groups in the backbone chain is formed by the acetal formation reaction between 4,4-dinitrovaleric acid (DNVA) and an acetylene-containing alcohol (AA).
[0017] The acetal formation reaction may be carried out under the conventional reaction conditions known in this field of art and thus an energetic reactive plasticizer comprising ester groups in the backbone chain is synthesized.
[0018] The acetylene-containing alcohol used in the above reaction includes for example, propargyl alcohol (n=1) and 3-butyn-1-ol(n=2), resulting in prop-2-yn-1-yl-4,4-dinitropentanoate (PDNP) or but-3-yn-1-yl-4,4-dinitropentanoate (BDNP), respectively.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 is a plot showing viscosity changes of GAP polyol prepolymer, prepared PDNP and a mixture thereof (1:1 by weight) over temperature, respectively, as measured in the test example 1.
[0020] FIG. 2 is a plot showing changes in glass transition temperature of GAP polyol prepolymer depending on the content of the prepared plasticizer measured as in the test example 2.
EXAMPLES
Preparation Example 1
Synthesis and Analysis of prop-2-yn-1-yl-4,4-dinitropentanoate (PDNP)
[0021] An energetic reactive plasticizer, prop-2-yn-1-yl-4,4-dinitropentanoate was synthesized as shown in the following reaction scheme 2.
[0000]
[0022] 50 mL toluene, 4,4-dinitrovaleric acid (DNVA) (6.45 g, 33.56 mmol) and propargyl alcohol (PA) (5.64 g, 100.68 mmol) were placed into a 2-neck flask under nitrogen atmosphere, and then the mixture was refluxed for 24 hours. Water generated during reflux was continuously removed. After completing the reaction, the reactants were cooled, neutralized with 2N sodium hydroxide solution and extracted with ether. Thus extracted organic solution was washed with water and dried by using MgSO 4 ; the solvent was removed under reduced pressure; and the resultant was purified by column chromatography. The conformation of thus obtained energetic reactive plasticizer PDNP was identified by the following methods. 1 H and 13 C NMR were used to identify the molecular structure, resulting in: 1 H NMR (CDCl 3 , d, ppm): 2.11 (3H, —CH 3 ), 2.49 (1H, =C—H), 2.50 (2H, —CH 2 —COO—), 2.83 (2H, —CH 2 —CH 2 —), 4.677 (—O—CH 2 —). 13 C NMR (CDCl 3 , d, ppm): 22.4, 28.4, 31.6, 53.0, 75.8, 77.2, 118.8, 170.0.
Preparation Example 2
Synthesis and Analysis of but-3-yn-1-yl-4,4-dinitropentanoate (BDNP)
[0023] An energetic reactive plasticizer, but-3-yn-1-yl-4,4-dinitropentanoate was synthesized as shown in the following reaction scheme 3.
[0000]
[0024] 50 mL toluene, 4,4-dinitrovaleric acid (DNVA) (6.45 g, 33.56 mmol) and 3-butyn-1-ol (BO) (100.68 mmol) were placed into a 2-neck flask under nitrogen atmosphere, and then the mixture was refluxed for 24 hours. Water generated during reflux was continuously removed. After completing the reaction, the reactants were cooled, neutralized with 2N sodium hydroxide solution and extracted with ether. Thus extracted organic solution was washed with water and dried by using MgSO 4 ; the solvent was removed under reduced pressure; and the resultant was purified by column chromatography. The conformation of thus obtained energetic reactive plasticizer was identified by the following methods. 1 H and 13 C NMR were used to identify the molecular structure, resulting in: 1 H NMR (CDCl 3 , d, ppm): 1.99 (1H, =C—H), 2.10 (3H, —CH 3 ), 2.46 (2H, —CH 2 —CH 2 —), 2.49 (2H, —CH 2 —COO—), 2.82 (2H, —CH 2 —CH 2 —), 4.16 (2H, —O—CH 2 —). 13 NMR (CDCl 3 , d, ppm): 18.9, 22.4, 28.6, 31.6, 63.1, 70.6, 80.1, 119.0, 170.5.
[0025] Thus obtained plasticizer for the preparation of PBX and a prepolymer were mixed together in order to estimate the plasticization properties by measuring decrease in viscosity and glass transition temperature of said mixture, and the results were represented by the following test examples.
Test Example 1
Decrease in Viscosity of a Prepolymer Due to the Plasticizer
[0026] For measuring viscosity, a viscometer, MCR 301 from Anton Paar Physica Co. was used by using a parallel plate having a 1 mm gap (CP25-1-SN9356, diameter=25 mm) at the temperature range of 30-60° C. at a constant shear rate of 1.0 s −1 with a temperature elevation rate of 1° C./minutes. After measuring viscosity of GAP polyol prepolymer per se, viscosity of a mixture of the plasticizer obtained by the above preparation example 1 or 2 and the GAP polyol prepolymer (1:1 w/w) was measured, so as to determine the plasticization properties represented by the decrease in viscosity. The test results obtained from the case wherein a plasticizer obtained according to the preparation example 1, i.e. PDNP was applied were represented in FIG. 1 . As shown in FIG. 1 , as compared to viscosity of a GAP polyol prepolymer, viscosity of a mixture of the plasticizer prepared according to the present invention and a GAP polyol prepolymer was significantly lowered, over the whole temperature range measured, thereby showing the significant plasticizing effect of the synthesized plasticizer according to the present invention.
[0027] The plasticizing effect represented by the decrease in viscosity of a conventionally used energetic plasticizer such as BDNPF/BDNPA; BDNPF/BDNPDF; BDNPF/BDNBF was also shown in the following table 1 for comparison. Viscosity was measured under the same test conditions as described in relation with viscosity measurement of the plasticizer prepared according to the present invention. For reference, viscosity of GAP polyol prepolymer itself was 6,015 cP at 30° C. and 1,035.5 cP at 60° C., respectively.
[0000]
TABLE 1
Viscosity of a mixture of GAP polyol prepolymer/plasticizer(1:1
w/w) at 30° C. and 60° C.
Viscosity(cP)
Composition (1:1 w/w)
30° C.
60° C.
GAP:PDNP
224
76
GAP:BDNP
239
46
GAP:BDNPF/BDNPA
1,441
295
GAP:BDNPF/BDNPDF
1,211
197
GAP:BDNPF/BDNBF
1,351
274
BDNPF: bis(2,2-dinitropropyl) formal
BDNPA: bis(2,2-dinitropropyl) acetal
BDNPDF: bis(2,2-dinitropropyl) diformal
BDNBF: bis(2,2-dinitrobutyl) formal
[0028] As seen from Table 1, it can be confirmed that the PDNP and BDNP plasticizer prepared according to the present invention have an excellent viscosity lowering effect in the GAP polyol prepolymer.
Test Example 2
Compatibility of the Plasticizer with a Prepolymer Measured by Glass Transition Temperature
[0029] In FIG. 2 , the changes in glass transition temperature of GAP polyol prepolymer depending on the increase of the weight fraction of the above-prepared reactive plasticizer (REP) were represented. PDNP and BDNP synthesized according to the above preparation examples 1 and 2, respectively were used and the weight fraction thereof was 0.2, 0.35 and 0.5, respectively. One glass transition temperature was measured in every composition of the tested plasticizer/prepolymer mixture, and it was confirmed that the obtained glass transition temperature met the Fox equation. This shows that the plasticizer prepared according to the present invention is compatible with GAP polyol prepolymer and has plasticizing effect on GAP polyol prepolymer.
INDUSTRIAL APPLICABILITY
[0030] The energetic reactive plasticizer according to the present invention is designed to be present in a form bound to the polymeric binder through covalent bond with the branch of the polymeric backbone of polymeric binder during a curing process, so as to prevent a conventional migration or exudation problem of an energetic plasticizer from the molded plastic PBX, while ensuring the essential physical properties required in an energetic plasticizer used in plastic PBX preparation, such as increased energy density and enhanced processability by lowered viscosity in a blending process.
[0031] When the energetic reactive plasticizer according to the present invention is applied to the plastic PBX preparation, the conventional plasticizer migration problem from plastic PBX can be prevented, leading to further advantageous effects such as an improvement in long term storage property of PBX and energy density increase in the whole composition.
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Disclosed is an energetic reactive plasticizer for a plastic bonded explosive (PBX), and specifically an energetic reactive plasticizer for PBX which has high performance and insensitiveness without a plasticizer migration by being bonded with a polymer binder for a plastic bonded explosive.
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BACKGROUND ART
[0001] The present invention relates to sliding type constant velocity universal joints for use in power transmission mechanisms, for example, in automobiles and various kinds of industrial machines that allow axial displacement and angular displacement between two axes on the driving side and the driven side.
[0002] A power transmission mechanism that transmits power from the engine of an automobile to a drive wheel must respond to angular displacement and axial displacement based on changes in the relative positional relation between the engine and the wheel. Therefore, for example as shown in FIG. 21 , an intermediate shaft 1 is interposed between the engine side and the drive wheel side, one end of the intermediate shaft 1 is coupled to a differential 3 through a sliding type constant velocity universal joint 2 , and the other end thereof is coupled to the drive wheel 6 through a fixed type constant velocity universal joint 4 and a wheel bearing 5 .
[0003] In the sliding type constant velocity universal joint 2 described above, not only angular displacement but also axial displacement is absorbed by so-called plunging, while in the fixed type constant velocity universal joint 4 , only the angular displacement can be absorbed. The sliding type constant velocity universal joint 2 , the fixed type constant velocity universal joint 4 , and the intermediate shaft 1 constitute a drive shaft 7 as a unit, and as the drive shaft 7 is mounted in the vehicle body, the constant velocity universal joints 2 and 4 are set at prescribed operation angles. The operation angles of the constant velocity universal joints 2 and 4 sequentially change, and therefore, in general, among these joints 2 and 4 , the fixed type constant velocity universal joint 4 is used on the outboard side and the sliding type constant velocity universal joint 2 is used on the inboard side to respond to the changing operation angles.
[0004] A double offset type constant velocity universal joint (DOJ) is well known as the sliding type constant velocity universal joint 2 . As shown in FIGS. 22 a and 22 b , the constant velocity universal joint includes, as essential elements, a joint outer ring 8 attached to a differential 3 on the vehicle body side, a joint inner ring 9 attached to one end of the intermediate shaft 1 , a plurality of balls 10 incorporated between the joint outer ring 8 and the joint inner ring 9 , and a cage 11 interposed between the joint outer ring 8 and the joint inner ring 9 to support the balls 10 . Note that a lid 16 to cover the opening is provided at the end of the joint outer ring 8 on the differential side.
[0005] The joint outer ring 8 is in the shape of a cup having a plurality of linear track grooves 12 parallel to its axial line and in its inner circumference at equal intervals in its circumferential direction. A plurality of linear track grooves 13 parallel to its axial line and corresponding to the track grooves 12 are provided in the outer circumference of the joint inner ring 9 . The track grooves 12 and 13 in the joint outer ring 8 and the joint inner ring 9 cooperate with each other to define ball tracks in which the balls 10 transmitting torque are provided. The balls 10 are supported in the cage 11 interposed between the joint outer ring 8 and the joint inner ring 9 . In the constant velocity universal joint, when an operation angle is set between the joint outer ring 8 and the joint inner ring 9 , the cage 11 controls the balls 10 to be on the bisector plane of the operation angle so that the constant velocity is maintained.
[0006] Various types of rings may be used for the joint outer ring 8 in the constant velocity universal joint 2 depending on how the joint is attached to the vehicle body, and the one shown in FIGS. 22 a and 22 b is of flange type. The flange type joint outer ring 8 has protruding vehicle body attachment flanges 14 integrally formed at equal intervals in the circumferential direction at the outer circumferential end, and is attached to the differential 3 (see FIG. 21 ) by fastening bolts using the bolt holes 15 formed through the flanges 14 . In the field of constant velocity universal joints, products having a joint outer ring 8 with a flower outer circumferential shape formed corresponding to the inner circumferential shape have been used in order to meet recent demands for lightweight and compact products (see for example, Japanese Patent Laid-Open Application No. Hei 5-231436).
[0007] The constant velocity universal joint having the flange type joint outer ring 8 has the plurality of vehicle body attachment flanges 14 protruding radially outwardly at the outer circumference of the joint outer ring 8 as described above, and the bolts are inserted through the bolt holes 15 in the vehicle body attachment flanges 14 for attachment to the differential on the vehicle body side.
[0008] As shown in FIGS. 23 a and 23 b , when the bolts are fastened to attach the joint outer ring 8 , a fastening tool (socket 18 as shown) is used, and therefore there should be a space a from the outer circumference of the joint outer ring 8 for inserting the tool. Therefore, in consideration of the attaching process using the fastening tool, the necessity of providing the space a from the outer side of the joint outer ring 8 and the bolt holes 15 in the flanges 14 causes the outer diameter size of the vehicle body attachment flanges 14 to increase, which increases the weight of the constant velocity universal joint.
[0009] In the constant velocity universal joint, the number of balls 10 is typically six or eight, and the balls 10 are normally arranged in the circumferential direction at six equal pitch intervals (60°) or eight equal pitch intervals (45°). In this constant velocity universal joint, as shown in FIG. 23 b , the balls 10 are provided at equal pitch intervals of 60°. If the number of the balls is not six or eight, the balls are arranged at equal pitch intervals in the circumferential direction.
[0010] In the constant velocity universal joint of this kind, when the torque is loaded and rotation is carried out, in other words, when power is transmitted, thrust force is induced in the axial direction of the constant velocity universal joint (induced thrust force), and the induced thrust force changes as many times as the number of the track grooves in one rotation. In the conventional constant velocity universal joint, the track grooves are arranged at equal intervals of 60°, and therefore the number of vibration frequency is six, which sometimes causes unnerving vibrations or muffled noises in resonance with the natural vibration frequency of the underbody of the vehicle.
DISCLOSURE OF THE INVENTION
[0011] An object of the present invention is to provide a constant velocity universal joint that can readily achieve reduction of the weight and size thereof by reducing the outer diameter of the joint outer ring using simple means.
[0012] The invention is directed to a constant velocity universal joint including an outer member provided with a plurality of track grooves formed in an inner circumference thereof, an inner member provided with track grooves corresponding to the track grooves of the outer member in an outer circumference, a plurality of balls provided in ball tracks defined by cooperation of the track grooves between the outer member and the inner member to transmit torque, and a cage having pockets for retaining the balls. The constant velocity universal joint has a plurality of vehicle body attachment flanges provided apart in a circumferential direction at an outer end of said outer member so as to outwardly protrude partially. In the universal joint, the outer circumferential shape of the outer member is in a flower shape corresponding to the inner circumferential shape, and the vehicle body attachment flanges are formed at outer circumferential recesses positioned between the track grooves of the outer member.
[0013] According to the present invention, since the outer circumferential shape of the outer member is formed in a flower shape corresponding to the inner circumferential shape, the weight thereof can be reduced while the load capacity of the constant velocity universal joint is maintained in the present level. In addition, the vehicle body attachment flanges provided at the outer circumferential recesses between the track grooves in the outer member in the flower shape allows the outer diameter size of the vehicle body attachment flanges to be reduced, and therefore the constant velocity universal joint can be more compact. Therefore the weight reduction and compactness of the constant velocity universal joint can improve the performance of the constant velocity universal joint and expand the applicable field thereof.
[0014] Regarding the outer circumferential shape of the outer member according to the invention, the ratio DN/DT of the outermost diameter size DT where the track grooves are positioned and the innermost diameter size DN where the vehicle body attachment flanges are located is desirably set in the range of from 0.85 to 0.95. The ratio of the outermost diameter size and the innermost diameter size is defined in the above-described range, so that the weight and size can be reduced as described above and the strength of the outer member can be secured.
[0015] Relative to the number of the track grooves of the outer member described above, an arbitrary number of the vehicle body attachment flanges can be provided. In other words, instead of providing vehicle body attachment flanges in all the outer circumferential recesses positioned between the track grooves of the outer member, vehicle body attachment flanges may be provided only in part of the outer circumferential recesses.
[0016] The present invention is applicable to a constant velocity universal joint having eight balls incorporated. With the eight balls, the ball PCD can be reduced as compared to a constant velocity universal joint with six balls and the size can effectively be reduced.
[0017] Another object of the invention is to attempt to improve countermeasure against the unnerving vibrations, muffled noises and the like.
[0018] According to the invention, a constant velocity universal joint includes an outer member having a plurality of axially extending track grooves formed in a cylindrical inner circumferential surface thereof, an inner member having a plurality of axially extending track grooves in a spherical outer circumferential surface thereof, balls each incorporated in a ball track formed by a pair of the track groove of the outer member and the track groove of the inner member, and a cage having pockets for holding the balls. The center of the outer spherical surface of the cage and the center of the inner spherical surface are offset from each other by an equal distance axially in the opposite directions from the cage center. The number of the balls is six, and the pitches of the ball tracks are random unequal pitches that are at least 55°. In the DOJ type, sliding type constant velocity universal joint, the track grooves of the outer member and the track grooves of the inner member are arranged with unequal pitches in the circumferential direction, so that in the DOJ with six balls, for example, the 6th order induced thrust force can be reduced, and vibrations and muffled noises in the vehicle can be prevented.
[0019] In the DOJ with six torque transmission balls, in order to reduce the 6th order induced thrust force described above, the track grooves of the outer member and the track grooves of the inner member may be arranged with unequal pitches in the circumferential direction (see Japanese Patent Laid-Open Publication No. Hei 1-50767), but simply providing the tracks with unequal pitches might prevent other important requirements (such as strength and durability) for the constant velocity universal joint from being satisfied. The pitch between ball tracks that can satisfy the strength, durability, and NVH characteristics of a constant velocity universal joint should be at least 55°. In this case, the positions of the pockets of the cage should be in phase with the pitches of the track grooves of the outer member and the track grooves of the inner member. Note that this applies to products with the maximum operation angle in the range of from 20 to 25°, and the upper limit for the ball track pitch is 55° in order to secure the inter-pocket column width W 1 of the cage and the inter-track spherical surface width W 2 of the inner member. If the ball track pitch is less than 55°, the inter-pocket column width W 1 of the cage ( FIG. 9 a ) and the spherical surface width W 2 of the inner member ( FIG. 8 a ) are too small, and sufficient strength for a constant velocity universal joint cannot be provided.
[0020] The invention is characterized in that, in the constant velocity universal joint, the ball track pitch is a random unequal pitch within the range of 60°±3°. Since the pitches of the track grooves of the outer member and the track grooves of the inner member are set to 60°±3°, the pockets of the cage can have an equal window length and an equal pitch (60°). Note that this applies to constant velocity universal joints with the maximum operation angle in the range of from 20 to 25°. The ball track pitch is limited to the range of 60°±3° in order to secure the inter-pocket column width W 3 ( FIG. 12 a ) necessary for securing the strength of the cage.
[0021] The invention is characterized in that, in the constant velocity universal joint, the pockets are provided with equal pitch in the circumferential direction and the window lengths are equal to each other. In this case, the window length L 2 of the pocket is set in consideration of deviations between track pitches (60°±3°) and the circumferential movement of the ball based on the maximum operation angle of the constant velocity universal joint. When the pockets of the cage have an equal window length, and can be set at equal pitch intervals, the constant velocity universal joint can be assembled significantly easily. More specifically, the outer member and the inner member need only be in phase.
[0022] The invention is characterized in that, in the constant velocity universal joint, in a section including the axial line of the joint, the inner spherical surface of the cage has the center of curvature in a location radially shifted from the center of curvature of the spherical outer circumferential surface of the inner member, and is formed with a greater radius of curvature than that of the spherical outer circumferential surface of the inner member. Here, axial clearances δ 2 +δ 2 ′ in the range of from 5 to 50 μm are provided between the ball and the pocket of the cage. In this way, axial clearances δ 1 and δ 1 ′ are provided between the inner member and the cage, and the slide resistance in the joint is significantly reduced. Therefore, even when the constant velocity universal joint is used for a drive wheel in an automobile, and a relatively small torque is loaded for example during idling in an AT automobile, vibrations from the engine side can be absorbed and prevented from being transmitted to the vehicle body, and therefore the vibration of the vehicle body can be prevented.
[0023] The invention is characterized in that, in the constant velocity universal joint, the inner circumferential surface of the cage is formed by connecting the cylindrical surface extending for an arbitrary axial size in the center, and the spherical outer circumferential surface of the inner member and a partial spherical surface having the same radius of curvature located on the sides of the cylindrical surface, and axial clearances δ 2 +δ 2 ′ in the range of from 5 to 50 μm are provided between the ball and the pocket of the cage. In this way, axial clearances δ 3 and δ 3 ′ are provided between the inner member and the cage, so that the slide resistance in the joint is significantly reduced. Even when the constant velocity universal joint is used for a drive wheel in an automobile, and a relatively small torque is loaded for example during idling in an AT automobile, vibrations from the engine side can be absorbed and prevented from being transmitted to the vehicle body, and therefore the vibration of the vehicle can be prevented.
[0024] According to the invention, in the DOJ type, sliding type constant velocity universal joint having a plurality of balls, the pitch of the ball track formed by a pair of the track groove of the outer member and the track groove of the inner member is randomly set in such a range that various characteristics (such as strength, durability, and NVH) necessary for a constant velocity universal joint are provided as described above. In this way, the vibration cycle by induced thrust force is not constant, so that the vibrations, muffled noises, and the like in the vehicle can be reduced.
[0025] FIGS. 15 to 20 show measurement results of induced thrust force for a conventional DOJ with six balls and the inventive product with six balls. In these figures, the abscissa represents the operation angle (0° to 15°), and the ordinate represents induced thrust (N). The broken line represents the measurements for the conventional product, and the solid line represents the measurements for the inventive product. In the inventive product, not only the 6th order induced thrust force can sufficiently be reduced, but also the induced thrust force in all the other orders are not more than that of the conventional product. The ball track pitch in the inventive product is as shown in Example 1 in Table 1. Note that measurement was carried out for combinations in Examples 2 to 4 in Table 1, and substantially the same effect as that in Example 1 was observed.
TABLE 1 Pitch Example 1 Example 2 Example 3 Example 4 α 1 55 55 55 58 α 2 70 65 59 61 α 3 55 55 65 61 α 4 55 65 61 63 α 5 70 55 57 60 α 6 55 65 63 57
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 a is a front view showing an embodiment of a joint outer ring of a constant velocity universal joint according to the present invention.
[0027] FIG. 1 b is a sectional view taken along the line A-O-B in FIG. 1 a.
[0028] FIG. 2 a is a diagram for comparison in the size of a joint outer ring between a conventional product and the inventive product, wherein is a front view showing the conventional product in the left part from the line X-X as the boundary and the inventive product in the right part.
[0029] FIG. 2 b is a diagram for comparison in the size of a joint outer ring between a conventional product and the inventive product, wherein is a sectional view showing the conventional product in the upper part above the line Y-Y as the boundary and the inventive product in the lower part.
[0030] FIG. 3 is a front view of a six-ball constant velocity universal joint having three vehicle body attachment flanges showing another embodiment of the present invention.
[0031] FIG. 4 is a front view of an eight-ball constant velocity universal joint having eight vehicle body attachment flanges showing another embodiment of the present invention.
[0032] FIG. 5 is a front view of an eight-ball constant velocity universal joint having four vehicle body attachment flanges showing another embodiment of the present invention.
[0033] FIG. 6 is a front view of a six-ball DOJ according to an embodiment of the invention.
[0034] FIG. 7 is a longitudinal sectional view of the DOJ shown in FIG. 6 .
[0035] FIG. 8 a is a cross sectional view of the inner member in the DOJ of FIG. 6 .
[0036] FIG. 8 b is a longitudinal sectional view thereof.
[0037] FIG. 9 a is a front view of the cage in the DOJ of FIG. 6 .
[0038] FIG. 9 b is a longitudinal sectional view thereof.
[0039] FIG. 10 is a front view of a six-ball DOJ according to another embodiment.
[0040] FIG. 11 a is a cross sectional view of the inner member in the DOJ of FIG. 10 .
[0041] FIG. 11 b is a longitudinal sectional view thereof.
[0042] FIG. 12 a is a front view of the cage in the DOJ of FIG. 10 .
[0043] FIG. 12 b is a cross sectional view thereof.
[0044] FIG. 13 is a longitudinal sectional view of an inner ring and a cage according to another embodiment.
[0045] FIG. 14 is a longitudinal sectional view of an inner ring and a cage according to yet another embodiment.
[0046] FIG. 15 is a graph representing measurement results for a 1st order component of induced thrust.
[0047] FIG. 16 is a graph representing measurement results for a 2nd order component of induced thrust.
[0048] FIG. 17 is a graph representing measurement results for a 3rd order component of induced thrust.
[0049] FIG. 18 is a graph representing measurement results for a 4th order component of induced thrust.
[0050] FIG. 19 is a graph representing measurement results for a 5th order component of induced thrust.
[0051] FIG. 20 is a graph representing measurement results for a 6th order component of induced thrust.
[0052] FIG. 21 is a cross sectional view of a sliding type constant velocity universal joint that constitutes a drive shaft of an automobile.
[0053] FIG. 22 a is a cross sectional view taken along the line C-O-D in FIG. 22 b showing a conventional sliding type constant velocity universal joint.
[0054] FIG. 22 b is a partly omitted front view showing a joint outer ring of a conventional sliding type constant velocity universal joint.
[0055] FIG. 23 a is a cross sectional view showing the state in which a bolt and a socket are mounted to the joint outer ring of FIG. 22 a.
[0056] FIG. 23 b a front view thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0057] Embodiments of the constant velocity universal joint according to the present invention shown in FIGS. 1 to 5 will be described in detail. The same or corresponding parts as or to those in the conventional constant velocity universal joints shown in FIGS. 22 a , 22 b , 23 a , and 23 b will be denoted by the same reference numerals.
[0058] A sliding type constant velocity universal joint according to the embodiment shown in FIGS. 1 a and 1 b is a double offset type constant velocity universal joint (DOJ) that constitutes a drive shaft 7 (see FIG. 21 ) serving as a power transmission mechanism in an automobile and is coupled to a differential 3 on the vehicle body side. The constant velocity universal joint includes, as essential elements, a joint outer ring 21 as an outer member attached to the differential 3 on the vehicle body side, a joint inner ring 9 as an inner member attached to one end of an intermediate shaft 1 , a plurality of balls 10 incorporated between the joint outer ring 21 and the joint inner ring 9 , and a cage 11 interposed between the joint outer ring 21 and the joint inner ring 9 to support the balls. (refer to FIGS. 22 a , 22 b , 23 a , and 23 b , because the structure is the same as the conventional structure except for the joint outer ring 21 .)
[0059] The joint outer ring 21 is in the shape of a cup having a plurality of linear track grooves 22 parallel to its axial line and in its inner circumference at equal intervals in the circumferential direction. The joint inner ring 9 has a plurality of linear track grooves 13 parallel to its axial line and corresponding to the track grooves 22 in its outer circumference. The track grooves 22 and 13 in the joint outer ring 21 and the joint inner ring 9 cooperate with each other to define the ball tracks in which the torque transmitting balls 10 are provided. The balls 10 are supported in the pockets of the cage 11 interposed between the joint outer ring 21 and the joint inner ring 9 . In the constant velocity universal joint, when an operation angle is provided between the joint outer ring 21 and the joint inner ring 9 , the cage 11 controls the balls 10 to be on the bisector plane of the operation angle, so that the constant velocity is maintained.
[0060] The joint outer ring 21 in the constant velocity universal joint is classified as a flange type ring based on how it is attached to the vehicle body. The flange type joint outer ring 21 uses a plurality of vehicle body attachment flanges 23 integrally provided at equal intervals in its circumferential direction at the outer end portion, and is attached to the differential 3 (see FIG. 21 ) by bolts fastened through bolt holes 24 formed through the vehicle body attachment flanges 23 .
[0061] The joint outer ring 21 has a flower outer circumferential shape formed corresponding to the shape of the inner circumference (track grooves) for reducing the weight and size. Herein, the “flower shape” refers to a shape that has recesses 25 that are formed, between the positions of the track grooves 22 formed in the inner circumference, at the outer circumferential surface of the joint outer ring 21 so as to extend along the track grooves 22 . The vehicle body attachment flanges 23 are provided at the outer circumferential recesses 25 positioned between the track grooves 22 of the joint outer ring 21 .
[0062] In this way, the joint outer ring 21 has the flower outer circumferential shape corresponding to the inner circumferential shape, so that the constant velocity universal joint can be reduced in weight with its load capacity maintained in the present level. In addition, the vehicle body attachment flanges 23 are provided at the outer circumferential recesses 25 positioned between the track grooves 22 in the flower joint outer ring 21 , so that the outer diameter size of the vehicle body attachment flanges 23 can be reduced and the constant velocity universal joint can be made compact.
[0063] FIG. 2 shows the conventional joint outer ring 8 and the inventive joint outer ring 21 as they are compared in size. In FIG. 2 a , the left part from the line X-X as the boundary shows the conventional product and the right part shows the inventive product. In FIG. 2 b , the upper part above the line Y-Y as the boundary shows the conventional product, and the lower part shows the inventive product.
[0064] In the comparison between the conventional product and the inventive product, the load capacity (size) of the constant velocity universal joint and the space a for inserting the tool are the same. In the comparison in the outer diameter size between the vehicle body attachment flanges 14 and 23 , the inventive product can be reduced by about 10% with respect to the conventional product in size, and by about 20% in weight.
[0065] Herein, the joint outer ring 21 of the inventive product has a flower outer shape that is advantageous in terms of weight reduction, but the shape has a limitation in thickness in order to keep certain strength. More specifically, in order to reduce the weight by employing the flower shape and still keep satisfactory strength for the constant velocity universal joint, not only the thickness of the track groove portions but also the thickness of the portion between the track grooves is crucial.
[0066] Therefore, as shown in FIG. 1 a , the ratio DN/DT of the outermost diameter size DT where the track grooves 22 are located and the innermost diameter size DN where the vehicle body attachment flanges 23 are located between the track grooves 22 should be set in the range of from 0.85 to 0.95. When the ratio of the outermost diameter size DT and the innermost diameter size DN is set in the above-described range, the weight and size can be reduced and the strength of the joint outer ring 21 can be secured simultaneously.
[0067] If the ratio DN/DT is smaller than 0.85, the portion of the joint outer ring 21 where the flanges 23 are located is too thin to provide strength required by the constant velocity universal joint. If the ratio DN/DT is greater than 0.95, the outer diameter size of the vehicle body attachment flanges 23 is too large, and the weight and size cannot be reduced.
[0068] Note that the number of the vehicle body attachment flanges 23 can arbitrarily be set based on the number of the track grooves 22 (balls 10 ) of the joint outer ring 21 described above. More specifically, instead of providing the vehicle body attachment flanges 23 in all the outer circumferential recesses 25 positioned between the track grooves 22 for all the track grooves 22 in the joint outer ring 21 as shown in FIGS. 1 a , 1 b , 2 a , and 2 b , vehicle body attachment flanges 23 may be provided only in part of the outer circumferential recesses 25 . For example as shown in FIG. 3 , the vehicle body attachment flanges 23 may be provided in three outer circumferential recesses 25 arranged at equal intervals in the circumferential direction of the joint outer ring 21 .
[0069] In the above example, although six balls 10 are incorporated in the constant velocity universal joint, the embodiment may be applied to a constant velocity universal joint in which eight balls 10 are incorporated. With eight balls 10 , the ball PCD may be reduced and the joint may be more compact than the constant velocity universal joint with six balls. In this case, vehicle body attachment flanges 23 may be provided in all the eight outer circumferential recesses 25 as shown in FIG. 4 , or the flanges 23 may be formed in four outer circumferential recesses 25 at equal intervals in the circumferential direction of the joint outer ring 21 as shown in FIG. 5 .
[0070] A constant velocity universal joint of an embodiment of the invention shown in FIGS. 6 to 9 includes an outer ring 110 , an inner ring 120 , balls 130 , and a cage 140 as essential elements. The outer ring 110 is in the shape of a cup having one end opened and has a shaft portion 116 coupled to a rotating shaft on the opposite side to the open end. The inner circumferential surface 112 of the outer ring 110 is cylindrical, and six axially extending track grooves 114 are formed in the inner circumferential surface of the cylinder. The inner ring 120 has a spherical outer circumferential surface 122 , and six axially extending track grooves 124 are formed in the spherical outer circumferential surface 122 . The inner ring 120 has a serration hole 126 to couple with the rotating shaft. The track grooves 114 of the outer ring 110 and the track grooves 124 of the inner ring 120 are paired to define ball tracks, and one ball 130 is incorporated in each ball track. The balls 130 are interposed between the outer ring 110 and the inner ring 120 to transmit torque. The balls 130 are held in pockets 146 in the cage 140 . The cage 140 is in contact with the cylindrical inner circumferential surface portion 112 of the outer ring 110 at the outer spherical surface portion 142 , and in contact with the spherical outer circumferential surface 122 of the outer ring 120 at the inner spherical surface portion 144 . Therefore, angular displacement can be made between the outer ring 110 and the cage 140 and between the cage 140 and the inner ring 120 . A sub unit consisting of the inner ring 120 , the balls 130 , and the cage 140 can slide relative to the outer ring 110 in the axial direction of the outer ring 110 . As shown in FIG. 9 b , the center Oo of the outer spherical surface portion 142 of the cage 140 and the center Oi of the inner spherical surface portion 144 are offset from each other by an equal distance axially in the opposite directions from the center O of the pocket. Therefore, when the joint transmits torque at a certain operation angle, the balls are always located in the bisector plane of the angle formed by the rotating axis of the outer ring 110 and the rotating axis of the inner ring 120 , so that the constant velocity of the joint can be secured.
[0071] According to the embodiment, the pitches α 1 to α 6 of the ball tracks are random and not less than 55°. More specifically, as shown in FIGS. 6 and 8 , the pitches of the track grooves 114 of the outer ring 110 and the track grooves 124 of the inner ring 120 are random and not less than 55° (see Examples 1 to 3 in Table 1). The lower limit for the pitch is set as 55°, so that prescribed sizes for the spherical surface width W 2 of the inner ring 120 and the inter-pocket column width W 1 of the cage 140 necessary in consideration of the strength of the inner ring 120 and the cage 140 can be secured. According to the embodiment, as shown in FIG. 9 , the pitch of the pockets 146 of the cage 140 is also random and not less than 55° as with the pitches of the track grooves 114 of the outer ring 110 and the track grooves 124 of the inner ring 120 . Consequently, at the time of assembling the joint, the outer ring 110 , the inner ring 120 , and the cage 140 should be adjusted to be in phase. The window length L 1 of the pockets 146 of the cage 140 is equal. The window length L 1 of the pocket 146 is set in consideration of the circumferential movement of the ball 130 based on the maximum operation angle of the joint.
[0072] Now, an embodiment of the invention shown in FIGS. 10 to 12 will be described. Note that the basic structure of the DOJ is the same as that of the embodiment in FIGS. 6 to 9 , and therefore substantially the same elements or parts will be denoted by the same reference characters. As shown in FIGS. 10 and 11 , according to the embodiment, the pitches α 1 to α 6 of the track grooves 114 of the outer ring 110 and the track grooves 124 of the inner ring 120 are unequal pitches in the range of 60°±3° (see Example 4 in Table 1). When the pitch is limited to the range of 60°±3°, the necessary size for the inter-pocket column width W 3 in consideration of the strength of the cage 140 is secured. In this example, as shown in FIG. 12 , the pockets 146 of the cage 140 are provided at equal pitch intervals (60°), and the window length L 2 of the pockets 146 is equal. The window length L 2 of the pocket 146 is set in consideration of the deviation of the ball track pitch (60°±3°) and the circumferential movement of the balls 130 based on the maximum operation angle of the joint. The pockets 146 of the cage 140 are equal in length and provided with equal pitch, phase adjustment is necessary only for the outer ring 110 and the inner ring 120 at the time of assembling the joint, which can be carried out significantly easily.
[0073] According to an embodiment shown in FIGS. 13 and 14 , the inner ring 120 and the cage 140 can move axially relative to each other, and the balls are released from restriction, so that they can more easily turn. In the embodiment shown in FIG. 13 , the radius curvature (r) of the spherical outer circumferential surface 122 of the inner ring 120 is set to be smaller than the radius curvature (R) of the inner spherical surface portion 144 of the cage 140 , and the center of curvature of the spherical outer circumferential surface 122 of the inner ring 120 and the center of curvature of the inner spherical surface portion 144 of the cage 140 are radially shifted. In this way, axial clearances δ 1 and δ 1 ′ are formed between the outer spherical surface 122 of the inner ring 120 and the inner spherical surface portion 144 of the cage 140 , and the clearances δ 1 and δ 1 ′ allow the inner ring 120 to be axially displaced relative to the cage 140 .
[0074] In the embodiment shown in FIG. 14 , the inner circumferential surface of the cage 140 is formed by connecting a cylindrical surface 144 a for a size (L) in the axial direction in the center and partial spherical surfaces 144 b on its both sides. The radius of curvature (R) of the partial spherical surface 144 b is equal to the radius of curvature (r) of the spherical outer circumferential surface 122 of the inner ring 120 , and there is a clearance 63 and 631 between the spherical outer circumferential surface 122 of the inner ring 120 and the inner circumferential surfaces ( 144 a and 144 b ) of the cage 140 .
[0075] In the embodiment shown in FIGS. 13 and 14 , there are clearances δ 2 and δ 2 ′ between the wall of the cage 140 opposing the axial direction of the pocket 146 and the ball 130 . The clearances δ 2 and δ 2 ′ are set in the range of from 5 to 50 μm in order to release the ball 130 from restriction, and in consideration of the effect of collision between the ball 130 and the cage 140 . The upper limit for the clearances δ 2 δ 2 ′ is 50 μm because for a clearance larger than 50 μm, not only the striking noise caused by the collision between the ball 130 and the cage 140 is large, but also the stability of the cage 140 is impaired by the impact upon the collision, which gives rise to increased vibrations. The lower limit is 5 μm though it would be possible to set the lower limit to zero in theory since the ball 130 is to be released from restriction. This is for surely eliminating fastening allowance and securing δ 2 and δ 2 ′ for convenience of manufacture and maintenance.
[0076] In the embodiment shown in FIGS. 13 and 14 , the clearances δ 1 and δ 1 ′ or δ 3 and δ 3 ′ allow the inner ring 120 and the cage 140 to be relatively moved in the axial direction, and the ball 130 can turn without resistance as it is not restricted by the pocket 146 of the cage 140 , so that the slide resistance for the axial relative movement of the outer ring 110 and the inner ring 120 is very small. Therefore, vibrations from the engine side as the torque is loaded are absorbed by smooth, slight relative movement between the outer ring 110 and the inner ring 120 through the cage 140 and are not transmitted to the vehicle body. Since the slide resistance inside the joint is small, angular displacement and axial displacement are extremely smoothly carried out.
[0077] In the described embodiment, the six balls 130 are used, and the induced force can similarly be reduced by employing unequal pitches in cases other than where the number of the balls 130 is six. Note however that the range of setting the pitches is determined based on the relation between the number of balls 130 and the operation angle. The relation between the operation angle and the ball track pitch for a six-ball DOJ and an eight-ball DOJ is given in following Tables 2 and 3.
TABLE 2 Maximum operation Ball track pitch angle Pockets with Pockets with (°) unequal pitches equal pitch 15 to 20 at least 53° 60° ± 4° 20 to 25 at least 55° 60° ± 3° 25 to 30 at least 57° 60° ± 2°
[0078]
TABLE 3
Maximum
operation
Ball track pitch
angle
Pockets with
Pockets with
(°)
unequal pitches
equal pitch
15 to 20
at least 39°
45° ± 3°
20 to 25
at least 41°
45° ± 2°
25 to 30
at least 43°
45° ± 1°
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The outer diameter of a joint outer ring is reduced using simple means, so that a constant velocity universal joint that can easily be reduced in weight and size is provided. It is an object to improve the unnerving vibrations, muffled noises, and the like. The constant velocity universal joint includes a joint outer ring having a plurality of track grooves formed in the inner circumference, a joint inner ring provided with track grooves corresponding to the track grooves of the joint outer ring, a plurality of balls provided in the ball tracks interposed between the joint outer ring and the joint inner ring and formed by cooperation of the track grooves to transmit torque, and a cage having pockets for retaining the balls. In the constant velocity universal joint having a plurality of vehicle body attachment flanges provided apart from each other in the outer circumferential direction of the joint outer ring and partly protruding in the radial direction. The joint outer ring has a flower outer circumferential shape corresponding to the inner circumferential shape, and the vehicle body attachment flanges are provided at outer recesses positioned between the track grooves of the joint outer ring. In this joint, the number of the balls is six, and the pitches of the ball tracks are random, unequal and not less than 55°.
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BACKGROUND OF THE INVENTION
This invention relates generally to the production of viscous hydrocarbons from subterranean hydrocarbon-containing formations. Deposits of highly viscous crude petroleum represent a major future resource in the United States in California and Utah, where estimated remaining in-place reserves of viscous or heavy oil are approximately 200 million barrels. Overwhelmingly, the largest deposits in the world are located in Alberta Province, Canada, where the in-place reserves approach 1000 billion barrels from depths of about 2000 feet to surface outcroppings and occurring at viscosities in excess of one million c.p. at reservoir temperature. Until recently, the only method of commercially recovering such reserves was through surface mining at the outcrop locations. It has been estimated that about 90% of the total reserves are not recoverable through surface mining operations. Various attempts at alternative, in situ methods, have been made, all of which have used a form of thermal steam injection. Most pilot projects have established some form of communication within the formation between the injection well and the production well. Controlled communication between the injector and producer wells is critical to the overall success of the recovery process because in the absence of control, injected steam will tend to override the oil-bearing formation in an effort to reach the lower pressure area in the vicinity of the production well. The result of steam override or breakthrough in the formation is the inability to heat the bulk of the oil within the formation, thereby leaving it in place. Well-to-well communication has been established in some instances by inducing a pancake fracture. However, problems often arise from the healing of the fracture, both from formation forces and from the cooling of mobilized oil as it flows through a fracture toward the production well. At shallower depths, hydraulic fracturing is not viable due to lack of sufficient overburden. Even in the case where some amount of controlled communication is established, the production response is often unacceptably slow.
U.S. Pat. No. 4,037,658 to Andersen teaches a method of assisting the recovery of viscous petroleum, such as from tar sands, by utilizing a controlled flow of hot fluid in a flow path within the formation but out of direct contact with the viscous petroleum; thus, a solid-wall, hollow, tubular member in the formation is used for conducting hot fluid to reduce the viscosity of the petroleum to develop a potential passage in the formation outside the tubular member into which a fluid is injected to promote movement of the petroleum to a production position.
The method and apparatus disclosed by the Andersen '658 patent and related patents is effective in establishing and maintaining communication within the producing formation, and has been termed the "heated annulus steam drive", or "HASDRIVE" method. In the practice of HASDRIVE, a hole is formed in the petroleum-containing formation and a solid wall, hollow, tubular member is inserted into the hole to provide a continuous, uninterrupted flow path through the formation. A hot fluid is flowed through the interior of the tubular member out of contact with the formation to heat viscous petroleum in the formation outside the tubular member to reduce the viscosity of at least a portion of the petroleum adjacent the outside of the tubular member to provide a potential passage for fluid flow through the formation adjacent the outside of the tubular member. A drive fluid is then injected into the formation through the passage to promote movement of the petroleum for recovery from the formation.
U.S. Pat. No. 4,565,245 to Mims, describes a well completion for a generally horizontal well in a heavy oil or tar sand formation. The apparatus disclosed by Mims includes a well liner, a single string of tubing, and an inflatable packer which forms an impervious barrier and is located in the annulus between the single string of tubing and the well liner. A thermal drive fluid is injected down the annulus and into the formation near the packer. Produced fluids enter the well liner behind the inflatable packer and are conducted up the single string of tubing to the wellhead. The method contemplated by the Mims patent requires the hot stimulating fluid be flowed into the well annular zone formed between the single string of tubing and the casing. However, the inventors of the present invention believe such concentric injection of thermal fluid, where the thermal fluid is steam, would ultimately be unsatisfactory due to heat loss from the injected steam to the produced fluid and possible scaling in the production tubing due to inverse solubility and flashing of produced water to steam. Also, there is a possibility of scale deposition and build-up in the annulus.
Parallel tubing strings, the apparatus disclosed in U.S. Pat. No. 4,595,057 to Deming et al, is a configuration in which at least two tubing strings are placed parallel in the wellbore casing. Parallel tubing has been found to be superior in minimizing scaling and heat loss during thermal well operation.
Copending application Ser. No. 394,687, which is assigned to the assignee of the present application, achieves an improved heavy oil recovery from a heavy oil-containing formation utilizing a multiple tubing string completion in a single wellbore, such wellbore serving to convey both injection fluids to the formation and produce fluids from the formation. The injection and production would optimally occur simultaneously, in contrast to prior cyclic steaming methods which alternated steam and production from a single wellbore. The process disclosed in copending application Ser. No. 394,687, is termed the "Single Well Injection/ Production Steamflood", or "SWIPS". In the SWIPS process, it is not necessary the wellbore be substantially horizontal relative to the surface, but may be at any orientation within the formation. By forming a barrier to fluid flow within the wellbore between the terminus of the injection tubing string and the terminus of the production tubing string; and exhausting the injection fluid into the annulus near the barrier while injection perforations are at a distance along the wellbore from the barrier nearer the wellhead, the SWIPS wellbore casing is effective in mobilizing at least a portion of the heavy oil in the formation nearest the casing by conduction heat transfer.
The improved heavy oil production method disclosed by the copending application Ser. No. 394,687 is thus effective in establishing communication between the injection zone and production zone through the ability of the wellbore casing to conduct heat from the interior of the wellbore to the heavy oil in the formation nearer the wellbore. At least a portion of the heavy oil in the formation near the wellbore casing would be heated, its viscosity lower and thus have a greater tendency to flow. The single well method and apparatus of the SWIPS method and apparatus in operation therefore accomplishes the substantial purpose of an injection well, a production well, and a means of establishing communication therebetween. A heavy oil reservoir may therefore be more effectively produced by employing the method and apparatus of the SWIPS invention in a plurality of wells, each wellbore having therein means for continuous drive fluid injection, simultaneous produced fluid production and which incorporates multiple tubing strings within the wellbore casing.
There are several advantages of developing heavy oil and tar sand reserves through the method and apparatus of the SWIPS invention. A shorter induction period, usually a few days versus upward of several weeks or more, is possible with the SWIPS method over developing communication between a separate injection and production well. The distance between the injection point of injected fluid into the hydrocarbon-containing formation and the production point of produced fluids is distinctly defined in the SWIPS method, where the spacing between a separate injection and production well is less certain. Through the distinct feature of the wellbore casing conducting heat into at least a portion of the oil in the formation outside of the casing, there is less pressure and temperature drop between injection and production intervals, therefore production to the surface of produced fluids which retain more formation energy, is more likely accomplished with the SWIPS method and apparatus over previous separate well technology. In the production to the surface of formation fluids with the SWIPS method and apparatus, the production tubing temperature loss is significantly reduced through its location within the wellbore casing with the injection tubing string, and, therefore, bitumen and heavy oil in the produced fluids are less likely to become immobile and inhibit production to the surface.
The SWIPS method and apparatus, in practice along with conventional equipment of the type well known to persons experienced in heavy oil production for the generation of thermal fluids for injection and for treating of the resulting produced fluids would form a comprehensive system for recovery of highly viscous crude oil.
After drilling and completion of a SWIPS well which traverses a subterranean hydrocarbon bearing formation, it is desirable to develop fluid and thermal communication between the portion of the formation receiving injection fluid and the portion from which hydrocarbons are produced into the SWIPS wellbore. One means of achieving the advantageous result of quickly developing such communication is accomplished by flowing hot injection fluid into both strings of tubing from the steam source and pressuring the hot injection fluid into the formation through the wellbore perforations. In this manner, the hydrocarbon bearing formation is energized more rapidly than if injection fluid was pressured into the injection zone alone, from the injection tubing string only. When a predetermined quantity of injection fluid is flowed down both tubing strings and into the formation, flow of injection fluid into the production tubing string from the surface steam source may cease, the production tubing string may then be placed in flow communication with surface production facilities, and the flow reversed in the production tubing string within the SWIPS wellbore apparatus to transfer produced fluid from the hydrocarbon-bearing formation up the wellbore to the surface production facilities. In the continuous operation of the SWIPS method and apparatus, it is desired the system be controlled to optimize the amount of energy transferred from the injection fluid to the hydrocarbon-bearing formation. In a preferred embodiment of the SWIPS method where the injection fluid is steam, it is desired the steam fully condense within the formation and the introduction of uncondensed steam into the SWIPS wellbore be avoided. It has been determined that by maintaining the flow of produced fluid into the wellbore through the restriction of flow within the production tubing, a liquid seal in the form of liquid hydrocarbons and water is formed in the area surrounding the produced fluid inlet to the SWIPS wellbore. By avoiding the entry of uncondensed steam into the production tubing and SWIPS wellbore, the wire mesh sand screen or alternatively, a gravel pack, or other well completion material is protected from erosion and corrosion often caused by hot, high velocity fluid. By knowing the injection fluid pressure within the injection tubing string, the pressure required at the bottom of the SWIPS wellbore which ensures a liquid seal, may be calculated. By the method of the present invention, the SWIPS wellbore may be operated in a manner most efficient for conservation of pressure and temperature, and production of formation hydrocarbons.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view in cross section of the single well injection and production system.
FIG. 2 is an elevation view in cross section of the single well injection and production system in the initiation configuration showing fluid injection through multiple tubing strings.
FIG 3 is an elevation view in cross section of the single well injection and production system in the normal operational mode.
FIG. 4 is an elevation view in cross section of the single well injection and production system and control means during normal operation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the exemplary apparatus for practicing the SWIPS method, as depicted by FIG. 1, a subterranean earth formation 10 is penetrated by a wellbore having a casing 12. Perforations 20 and 22 provide fluid communication from the wellbore interior to the earth formation 10. A top packer 26 and bottom packer 28 are placed above the perforations 20 and 22, respectively.
A first tubing string 32 and a second tubing string 30 are placed within the wellbore casing 12, both tubing strings extending through top packer 26. Second tubing string 30 terminates at a depth shallower in the wellbore than bottom packer 28. An annular-like injection fluid flow path 36 is created by the space bounded by the top packer 26, bottom packer 28, and within the wellbore casing 12 exterior of either tubing string. Second tubing string 30 further extends through bottom packer 28, terminating at a depth below bottom packer 28.
When pressured injection fluid from a fluid supply source (not shown) is supplied to first tubing string 32, the injection fluid flows down first tubing string, and exhausts from the terminus of the tubing string into the annular-like fluid flow path 36. Continual supply of high pressure injection fluid to the first tubing string 32 forces the injection fluid upward in the annular flow path 36, toward the relatively lower pressured earth formation 10, through casing perforations 20. In the preferred embodiment of the SWIPS method, the injection fluid is steam. When the steam flows up the annular path 36 bounded by casing 12, thermal energy is conducted through the wellbore casing 12, and heating at least a portion of the earth formation 10 near the wellbore casing 12.
Hydrocarbon-containing fluid located within the earth formation 10 near the wellbore casing 12, having now an elevated temperature and thus a lower viscosity over that naturally occurring, will tend to flow along the heated flow path exterior of the casing 12 formed near the wellbore casing 12 by heat conducted from steam flow in the annular-like flow path 36 on the interior of the casing 12, toward the relatively lower pressure region near perforations 22. In the operation of the preferred embodiment of the SWIPS method and apparatus, produced fluids comprising hydrocarbons and water, including condensed steam, enter from the earth formation 12 through casing perforations 22 to the interior of the wellbore casing 12 below bottom packer 28. Produced fluid is continuously flowed into second tubing string 30 and up the second tubing string to surface facilities (not shown) for separation and further processing.
Referring now to FIG. 2, in a preferred method of establishing communication between the portion of the subterranean earth formation subjected to injection fluid, and the lower portion from which fluids will be produced, steam from an injection fluid supply source (not shown) is flowed from the surface down both the first tubing string 32 and the second tubing string 30. Injection fluid in the first tubing string 32 flows from the terminus of the first tubing string 32 along the annular-like flow path 36, exhausting from the SWIPS wellbore into the hydrocarbon-bearing formation through perforations 20. For at least a portion of the time during which injection fluid is flowed into first tubing string 32 and injection fluid is also flowed into second tubing string 30 from a surface injection fluid supply source (not shown). During this time, injection fluid in the second tubing string 30 is exhausted at the tubing tail and enters the hydrocarbon-bearing formation through casing perforations 22.
Referring now to FIG. 3, when sufficient injection fluid has entered the hydrocarbon-bearing formation to reduce the viscosity of at least a portion of the reservoir fluid sought to be produced and sufficient energy exists in the formation, the second tubing string 30 is disconnected from the injection fluid supply source (not shown), and fluid communication is established between the second tubing string 30 and production facilities (not shown). Due to a decreased pressure now existing in the second tubing string 30 relative to the pressure within the hydrocarbon-containing formation 10, formation fluid will tend to flow from the hydrocarbon-containing formation 10 toward the terminus of the second tubing string 30 through perforations 22. It is preferred to minimize the duration of time between cessation of injection fluid flow through second tubing string 30 and the flowing of formation fluids in a reverse direction through second tubing string 30, in order to minimize the loss of thermal energy and thus minimize the flowing viscosity of the fluids produced from hydrocarbon-containing formation 10.
Referring now to FIG. 4, to avoid the entry of uncondensed steam into the gravel pack or wire mesh sand screen area located exterior of the wellbore near perforations 22, the level of formation fluid interface 40 at a sufficient distance in the hydrocarbon-bearing formation above perforations 22 is created and maintained. The level of interface 40 above perforations 22 is directly proportional to the difference in pressure between the injection fluid in first tubing string 32 and pressure at the bottom hole fluid inlet to second tubing string 30. It is thus possible to sense the pressure existing in second tubing string 30, compare it to the injection fluid pressure existing in first tubing string 32, or any point along the injection fluid flow path defined from the injection fluid supply source and the terminus of the first tubing string 32, and determine the level of the formation fluid interface 40 above perforations 22, based on the difference therebetween. In one embodiment, bottom hole pressure in the second tubing string 30 is sensed utilizing a well-known "bubble-tube" or "capillary tube" device which comprises a length of small diameter metallic tubing 42 extended from the surface to the downhole environment for which pressure information is desired. The indication of pressure existing at the downhole terminus of the small diameter metallic tubing 44 is transmitted via a gas, typically an inert gas such as nitrogen, to instrumentation 46 placed at the surface. Based upon the indicated pressure, an estimate of fluid level interface 40 height above the terminus 44 is used to control the amounts of fluid restriction applied to the produced fluid stream in the second tubing string 32 through incorporation of a surface control valve 48. Thus, the liquid level interface 40 is proportional to the difference in pressure (ΔP 1 ) between Steam Injection Pressure (SIP), and Bottomhole Pressure (BHP), and is represented by the equation:
ΔP.sub.1 =BHP-SIP.
By the method of the present invention, fluid interface is maintained at sufficient level above perforations 22 to form a liquid seal at the fluid entrance to the SWIPS wellbore, thus avoiding the contact of uncondensed injection fluid with the gravel pack, wire mesh sand screen or other well completion device which may be subject to damage from contact with hot or high velocity injection fluid.
Although the present invention has been described with preferred embodiments, it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of the present 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 appended claims.
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Production of viscous hydrocarbons is initiated by first injecting an injection fluid down at least two tubing strings in a wellbore having multiple tubing strings therein. Following an initiation phase, flow of injection fluid in the production tubing string is ceased, and production of formation fluid to the surface commenced in the heated tubing. The production of formation fluids is controlled, and entry of uncondensed steam from the formation into the wellbore avoided by maintaining a liquid level in the formation which is above the production perforations.
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BACKGROUND OF THE INVENTION
This invention relates in general to protectors for property and, in particular,for an inflatable protector for houses, trailers or other types of structures.
DESCRIPTION OF THE PRIOR ART
In the prior art various types of protectors for structures have been devised however, these structures have been expensive to construct and once constructed have had an unpleasant aesthetic appearance. Also, the prior art structures have proven inoperative in that they not only did not protect the property they enclosed, they were incapable of protecting themselves from such natural forces as hurricanes and tornadoes.
Various types of protective devices have been proposed in the prior art. For example, U.S. Pat. No. 3,548,904 discloses a cargo blanket which includes fluid impervious compartments capable of being inflated to form a protective cover.
U.S. Pat. No. 3,783,766 discloses a bag-like cover which provides a sealed enclosure for equipment which is susceptible to atmospheric deterioration.
U.S. Pat. No. 4,206,575 discloses an insulating and weatherproof cover for a mobile home which has an outer waterproof layer and an inner foam-type layer bonded thereto.
U.S. Pat. No. 4,283,888 discloses a covering of interlaced mineral fibers which forms a heat insulating and protected roof structure.
U.S. Pat. No. 4,858,395 discloses a fire resistant sheet which can be draped over a structure to envelope and protect the structure.
SUMMARY OF THE INVENTION
This invention consists of a framework that can be erected over the structure that is to be protected. The framework has a plurality of telescoping supports that are securely anchored to the ground. A plurality of inflatable panels, with rims attached, are designed to be attached to the telescoping supports and when inflated will enclose the structure to be protected. When deflated the panels and frames will be enclosed in a covered trench that encircles the structure to be protected.
It is an object of the present invention to provide an inflatable structure protector that is esthetically pleasing and unobtrusive when not in use.
It is also an object of the present invention to provide a structure protector that is easily and conveniently erected around the structure to be protected.
These and other objects and advantages of the present invention will be fully apparent from the following description, when taken in connection with the annexed drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a structure with the protective enclosure in its nonuse position.
FIG. 2 shows the protective enclosure in its in-use position.
FIG. 3 shows the holder for the inflatable portion of the protector and a portion of the protector in an inflated condition.
FIG. 4 shows the holder for the inflatable portion of the protector and a portion of the protector in an deflated condition.
FIG. 5 is a partial view of a part of the holder showing the air intake openings.
FIG. 6 is a partial view of another part of the holder.
FIG. 7 is a partial view of the inflated panels interlocked.
FIG. 8 is a partial view of one of the panels as it is interlocked and sealed at the bottom of the panel.
FIG. 9 is a view of one of the supporting posts for the protective enclosure.
FIG. 10 is a view of one of the supporting posts for the protective enclosure in an arched over position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows the present invention with some of the telescoping support posts 4 erected around the sides of a structure 2. Although only two telescoping support posts 4 are shown in FIG. 1, it is understood that this is for illustration purposes only. The total number of telescoping support posts 4 that will be used will depend on the size of the structure to be protected. Also, in FIG. 1 only the protective panel members 6 around the sides of the house are shown. It should be understood that other protective panel members 6 will also be placed at the front and the rear of the structure 2, but are not shown in FIG. 1 for the sake of clarity. Also shown in FIG. 1 are the air pumps 14 with air supply tube 27 which will supply air to the inflatable panel members 6 which will be explained below . Element 15 is a supply tank for hydraulic fluid and 16 is a supply pipe for supplying the hydraulic fluid to the telescoping support posts 4 as will be described below.
FIG. 2 shows the protective enclosure with the panel members 6 inflated and the telescoping support posts 4 fully extended to encircle and protect the structure 2 (shown in FIG. 1). It should be noted that the telescoping support posts 4 shown in FIG. 2 only have telescoping portions 5, 7, and 8 shown. The number of telescoping portions may vary depending on the size of the structure to be protected.
The telescoping support posts 4 can be made of a variety of material such as steel or plastic. The exact type of material is not critical to the invention except it must be able to withstand the forces that the protector is likely to encounter.
The panel members 6 are shown partially in FIGS. 3 and 4. it should be noted that the panels are shown as rectangular in the drawings, however, this shape is not critical and the panels can be other shapes such as, but not limited to, oval or circular. Actually the panel members 6 can be virtually any shape but the oval or rectangular shapes are preferred. Each panel member 6 consists of a composite bag-like structure that is air tight. The inner side 21 of the panel members 6 (that is the side that faces the structure 2) and the edges of the panel members 6 will be constructed of a rubber or plastic material. The outer side 22 of the panel members 6 (that is the side that faces away from the structure 2) will be constructed of a rubber or plastic material that has flexible steel belts woven throughout the material, similar to the way steel belts are woven into steel belted radial tires for an automobile.
The panel members 6 are shape in a bellows-like configuration (as seen in FIG. 4) so that they may expand or contract as air is pumped into or extracted from the panel members 6, as will be more fully explained below. Each panel member 6 has attached thereto a number of rim pieces 9. The exact number of rim pieces 9 will vary depending on the size of the panel members 6 and the size of the structure 2 to be protected.
The rim pieces 9 will be be made from metal such as steel or aluminum, or they could be made from a plastic such as Nylon or Teflon, and they will be vulcanized or otherwise permanently attached to the panel members 6. The ends of the rim pieces 9 are L-shaped and will interlock with the L-shaped recesses 10 within the carrier 26. The carriers 26 will be attached to the telescoping supports 4 by rings 13 connected to the carrier 26 by rods 12 which will raise the panel members 6 as the panel members 6 are inflated with air.
Each of the panel members 6 will have an opening which will connect to and be sealed with the opening 25 in element 11 connected to the carrier 26 so that air pipes or tubes 27, shown in FIG. 1, can connect an air pump 14 to each of the panels. A single air pump can be used to supply air to all the panels or multiple pumps can be used to supply air to different panels, depending on the size of the structure to be protected.
When not needed the telescoping supports 4 and the panel members 6 will be stored in a trench 3 (as seen in dotted lines in FIG. 1) that surrounds the structure 2. The trench can be lined with concrete or some other material that will prevent the sides from collapsing, and will be large enough to house the telescoping supports 4 and the panel members 6 and the various equipment needed to raise the telescoping supports 4 and the panel members 6, such as motors, gears, and hydraulic pumps.
Attached to each top of the panel members 6 will be a flange 23 which will interlock with a similar flange 24 on an adjacent panel member 6 to secure the panels together at the top of the structure to be protected (see FIG. 7) One of the panel members 6 can have a weight 17 attached in any conventional manner, which will help pull the bottom of the panel members 6 away from the top of the panel members 6 when it is necessary to lower the protective structure. The weight will help the interlocking panels disengage so the panels can be lowered when they are not needed.
Hydraulic lines 16 will be connected to one or more reservoirs 15 with appropriate pumps (not shown) that will supply pressure to raise the supports 4 from the trench 3 to surround the structure to be protected. The pumps could be operated by electricity but should have a battery back up in case the electric service is interrupted by a storm. The pumps could also be operated manually. The same would be true for the air pumps that supply air to inflate the panel members 6.
In addition, the lowermost panel member 6 would have a lip 20 which will engage a lip 18 on a support 19 (as shown in FIG. 8) which will be mounted within the trench 3. This would help seal and structurally support the bottom of the panel members 6.
When the structure protector is needed, the first step will be to activate the motors that will raise the telescoping supports 4, and at the same time start the air pumps that will inflate the panel members 6. The motors can be activated by any of the normal means such as switches, or the entire system could be controlled by a computer system. There could be a separate motor for panels and telescoping supports on each side and end of the structure or one motor could be connected to all the panels and telescoping supports depending on the size of the structure to be protected.
The panel members 6 will continue to expand until they reach the top of the structure where the interlocking flanges 23, 24 will engage. It should be noted that the flanges 23, 24 could be provided with cooperating sloped surfaces to make it easier for the top panels to ride over one another if needed.
Any natural forces, such as hurricanes and the resultant debris which are blown by the hurricane winds, which hit the structure protector will tend to be, first, channeled over the structure due to its arched shape. Second, the air trapped inside the panel members 6 will form an additional layer of protection, similar to the way a radially belted tire protects itself from road hazards such as curbs, glass, and nails.
As the telescoping supports are raised, the top most part 8 of the support, which is made from a coil spring like structure will bend (as shown in FIG. 10) from the weight of the emerging panels. This will allow the top of section 8 to move toward the center of the roof of the structure until the flanges 23, 24 on adjacent panel members 6 engage and interlock. The flanges can be helped to interlock by adjusting the amount of air in the panels and using the motors to raise and lower the telescoping supports. For example, once the flange 23 passes over the flange 24, a little air could be let out of the panels attached to flange 23. This will allow the flange 23 to sink toward the flange 24. Then by lowering the telescoping supports, the flanges 23, 24 will move relative to one another and inter lock.
When the storm is over, the structure protector can be removed in the reverse order from which it was erected. The telescoping supports will be raised until the flanges 23, 24 are clear of each other, air will be removed from the panels that the flange 24 is attached to until the weight 17 pulls the panels down to the point that flanges 23, 24 will not engage as the telescoping supports are lowered. The pneumatic pumps will be reversed so that air is removed from the panel members 6. As the air is removed, the panels will collapse back into the trench 3. Also, the hydraulic motors will be reversed to lower the telescoping supports 4 back fully into the trench.
Although the Structure Protector and the method of using the same according to the present invention has been described in the foregoing specification with considerable details, it is to be understood that modifications may be made to the invention which do not exceed the scope of the appended claims and modified forms of the present invention done by others skilled in the art to which the invention pertains will be considered infringements of this invention when those modified forms fall within the claimed scope of this invention.
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A framework that can be erected over the structure that is to be protected. The framework has a plurality of telescoping supports that are securely anchored to the ground. A plurality of inflatable panels, with rims attached, are designed to be attached to the telescoping supports and when inflated will enclose the structure to be protected. When deflated the panels and frames will be enclosed in a covered trench that encircles the structure to be protected.
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RELATED APPLICATION
This is a continuation application of U.S. patent application Ser. No. 10/179,603 filed Jun. 25, 2002 now U.S. Pat. No. 7,006,144, titled “Video Camera Recorder” and commonly assigned, the entire contents of which is incorporated herein by reference. In addition U.S. patent application Ser. No. 10/179,603 is a divisional application of U.S. patent application Ser. No. 09/264,587 filed Mar. 8, 1999 now U.S. Pat. No. 6,556,245, titled “Game Hunting Video Camera” and commonly assigned, the entire contents of which is also incorporated herein by reference.
TECHNICAL FILED OF INVENTION
This invention relates to a design of a video camera for recording game hunting. More specifically it relates to a video camera design that is mountable on a weapon so a hunter can records what he or she sees as he or she is hunting without the help of a third party and without the limitations of related art. Game hunting videos are very popular to the sportsman, both as an instruction tool and a way of capturing the hunt on film.
BACKGROUND OF INVENTION
A motion picture camera attached to the barrel of a rife is disclosed in the U.S. Pat. No. 3,427102 (Wade). This invention is cumbersome to use and is only designed to be attached to an elongated barrel of a firearm. Moreover, its use requires the operator to physically change the structure of the firearm.
A gun mounted video camera is disclosed in U.S. Pat. No. 4,835,621 (Black). This patent discloses a device that looks like a rifle but is really just a video camera recording device.
Video cameras mounted to firearms with head mounted video displays are disclosed in the following patents: U.S. Pat. No. 4,786,966 (Hanson), U.S. Pat. No. 4,884,137 (Hanson), U.S. Pat. No. 4,970,589 (Hanson), U.S. Pat. No. 5,005,213 (Hanson), U.S. Pat. No. 5,200,827 (Hanson), U.S. Pat. No. 5,711,104 (Schmitz). A similar invention is disclosed in U.S. Pat. No. 5,834,676 (Elliot). These patents relate to using a video camera to transmit a video signal to a head mounted video display for aiming purposes and are generally designed for military or police purposes not for recording game hunting.
The previous related art does not enable the use of a video camera for effectively recording game hunting under the conditions a game hunter is likely to encounter. The need for a simple and efficient way to record game hunting without hindering the hunt has long been felt. My present invention satisfies those needs.
BRIEF SUMMARY OF INVENTION
The above-mentioned problems with video camera systems and other problems are addressed by the present invention and will be understood by reading and studying the following specification.
In one embodiment, a camera is disclosed. The camera includes a display, a main camera body, a camera lens and a display housing. The display housing has a front side and a back side. The display is encased in the back side of the display housing. The main camera body has a front end and a back end. The display housing is movably connected to the main camera body. The camera lens is of a given diameter and is encased in the front end of the main camera body. The display housing has first and second positions relative to the camera lens. In the first position, the display housing covers the lens and in the second position, the lens is exposed.
In another embodiment, a camera comprises a main camera body, a lens a display housing and a display. The lens is received in the main camera body. The display housing is movably coupled to the main camera body to selectively cover and uncover the lens. The display is received in the display housing to display images received by the lens.
In further another embodiment, a camera lens and display apparatus is disclosed. The camera lens and display apparatus includes a lens, a display and a display housing. The lens is used to receive images and is received in a camera body. The display is used to display the received images. The display is received in the display housing. The display housing is movably coupled to the camera body to selectively cover and protect the lens and the display.
In yet another embodiment, a method of operating a camera is disclosed. The method comprising moving a display housing containing a display from a first position that covers a lens to a second position that uncovers the lens.
BRIEF DESCRIPTION OF DRAWINGS
The forgoing and other features and advantages will be apparent to those skilled in the art from the specification and the following illustrations of the preferred embodiments in which like reference numerals indicate like parts throughout the several views. Referring to the drawings:
FIG. 1 is a perspective view of the first preferred embodiment of the game hunting video camera in its non-operational mode.
FIG. 2 is a perspective view of the first preferred embodiment of the game hunting video camera in its operational mode.
FIG. 3 is a front view of the first preferred embodiment of the game hunting video camera in its operational mode.
FIG. 4 is a rear view of the first embodiment of the game hunting camera in its operational mode.
FIG. 5 is a perspective view of the first preferred embodiment illustrating how the cassette drive and battery are accessed.
FIG. 6 is a side cross-sectional representation of the components of the game hunting video camera.
FIG. 7 is a schematic diagram of the circuit that controls the video recorder and the liquid crystal display in the first embodiment of the game hunting video camera.
FIG. 8 is a side view of the second embodiment of the game hunting video camera in its non-operation mode.
FIG. 9 is a perspective view of the second embodiment of the game hunting video camera illustrating how the LCD housing member moves.
FIG. 10 is a perspective view of the second embodiment of the game hunting video camera in its operational mode.
FIG. 11 is a perspective cross-sectional view of the second embodiment of the game hunting video camera illustrating the mechanism that controls LCD housing member.
FIG. 12 is a block diagram of the mechanism that controls the movement of the LCD housing member for the second embodiment of the game hunting video camera.
FIG. 13 is an exploded view illustrating the bracket mount system.
FIG. 14 is a perspective view illustrating how the video camera is mounted on a barrel of a firearm.
FIG. 15 is an exploded cross-sectional view of the components of the mount system.
FIG. 16 is a bottom cross-sectional view of the mount system locked in place.
FIG. 17 is a bottom cross-sectional view of the mount system being released by the quick release buttons.
FIG. 18 is a perspective view of the first embodiment of the game hunting video camera mounted on a barrel of a firearm.
FIG. 19 is a perspective view of the first embodiment of the game hunting video camera mounted on a bow.
DETAILED DESCRIPTION
My first embodiment of my game hunting video camera invention, in its non-operational mode, is illustrated in FIG. 1 . The video camera is shown having a main camera body 10 , a camera weather cover 12 , a camera base 16 , a liquid crystal display housing member 18 , a liquid crystal display weather shield 20 , a camera mount member 14 , a zoom in button 22 and a zoom out button 24 . The video camera in its operational mode is illustrated in FIG. 2 . FIG. 3 illustrates the front side of the camera base 16 . The front side of the camera base 16 contains the lense 26 of the camera, a circular recess portion 34 , a front facing microphone 28 for recording the sounds produced by the game and normally closed SPDT push button camera record switch 30 that turns the video camera on and off.
An liquid crystal display housing member 18 is attached by hinges 11 to the camera base 16 . When the video camera is in its non-operational transportation mode, the liquid crystal display housing member 18 is rotated on its hinges 11 so it is in front of the camera base 10 as illustrated in FIG. 1 . When the liquid crystal display housing member 18 is in this position the normally closed camera record switch 30 is open and the video camera is off. The liquid crystal display housing member 18 is held in this position by a protruding circular semi pliable seal 32 that has one side solidly connected to the liquid crystal display housing member 18 as illustrated in FIG. 3 . The other side of the circular semi pliable seal 32 is tightly received in the circular recess 34 located in front of the camera base 16 . This seal connection not only keeps the liquid crystal display housing member 18 in the non-operational position, it also protects the lense 26 when the video camera is turned off. This is an important feature because the video camera is likely to be exposed to harsh environments as a hunter pursues his or her game. My design not only protects the lense 26 from scratches, as the hunter makes his or her way through the woods or brush, it also protects the lense from weather conditions.
When the hunter sees game he or she simply rotates the liquid crystal display housing member 18 about its hinges 11 . This action closes the camera record switch 30 completing the circuit that starts the video camera recording. The ease and speed in which the video camera is started is very important in a hunting situation because a hunter may not have much time to react when the game is sighted. My design minimizes the time needed to get the video camera recording. In addition, the hinges 11 are tightly bound so that the liquid crystal display housing member 18 is put in a position by the operator it will stay there until the operator once again acts upon it.
The back side of the camera base 16 and the liquid crystal display housing member 18 is illustrated in FIG. 4 . A rear microphone 19 is placed on the back side of the camera base 16 for recording the sounds produced by the hunter. The back side of the camera base 16 also has a indicator light 23 that lights up when the video camera is recording. A liquid crystal display 36 is encased in the back side of the liquid crystal display housing member 18 . The operation controls of the camera are also placed in the back side of the liquid crystal display housing member 18 around the liquid crystal display 36 . The operating controls are common in the art of video cameras and may include the following: a menu control 38 , a liquid crystal display brightness control 39 , a speaker control 40 , an on/off record switch 42 , a play control 44 , a search control 46 , a menu select dial 48 , a battery charge connect port 50 , a s-video terminal 52 , a audio out port 54 and a video out port 56 .
A weather shield is connected by pivots 27 on the back side of the liquid crystal display housing member 18 as illustrated in FIG. 4 . The liquid crystal display 36 is activated when the liquid crystal display weather shield 20 is rotated in an upward direction. This action closes the normally closed SPST push button liquid crystal display switch 25 activating the liquid crystal display 36 . Besides controlling the liquid crystal display switch 25 the liquid crystal display weather shields also shields the liquid crystal display 36 from the weather. In addition, the liquid crystal display weather shield 20 has a liquid crystal display weather shield tab portion 21 that protrudes out beyond the body of the liquid crystal display housing member 18 as illustrated in FIG. 3 . This tab portion allows the hunter to quickly flip the liquid crystal display weather shield 20 up to activate the liquid crystal display 36 . The pivots 27 are also tightly bound so that when the operator puts the weather shield in a position it will remain there until the operator once again acts upon it.
The circuit that turns the video recorder and the liquid crystal display 36 on and off is an important feature of my invention and is illustrated in FIG. 7 . A simplified circuit is shown having a battery source 60 , a video recorder portion, a liquid crystal display portion, a relay 68 , the camera record switch 30 , the on/off record switch 42 , the liquid crystal display switch 25 , an upper wire 72 and a lower wire 74 . The circuit is shown, having the liquid crystal display housing member 18 rotated in front of, and attached to, the camera base 16 . Accordingly, the normally closed camera recorder switch 30 is in its open position 71 . The circuit is also shown having the on/off switch 42 in its open position 75 . If this situation occurs, the relay 68 automatically acts on the on/off record switch 42 switching it to the closed position 77 . This ensures that every time the liquid crystal display housing member is rotated to the camera's operational position, the camera starts recording automatically. The operator will not have to waste time manually pushing the on/off record switch 42 on the liquid crystal display housing member 18 to get it in the right position. When the camera recorder switch 30 is in its closed position 73 and the on/off record switch 42 in its closed position 77 , the circuit is complete and the video camera starts recording. The liquid crystal display 36 is turned on when the liquid crystal display switch 25 is closed. This occurs when the liquid crystal display weather shield 20 is flipped up.
My video camera has a cylindrical weather cover 12 that screws onto the main camera base 10 . This is illustrated in FIG. 5 . As the weather cover 12 is screwed onto the main camera body 10 it comes in contact with a rubber ring 41 thereby sealing the internal components from the weather. The weather cover 12 also provides easy access to the cassette holder 58 and the battery 60 . The operator simply has to unscrew the weather cover 12 to put in a video cassette or replace the battery 60 . The main camera body 10 is also cylindrical in shape and houses the main components of a standard analog or digital video camera recorder known in the art. These components are illustrated in FIG. 6 .
The second embodiment of my invention is illustrated in FIG. 8 . Instead of the operator manually moving the liquid crystal display housing member 18 and the liquid crystal display weather shield 20 to activate the video recorder and the liquid crystal display 36 respectively, this embodiment uses electronic switches. FIG. 8 illustrates the video camera in the non-operational mode. In addition to the zoom in button 22 and the zoom out button 24 , the main camera body 10 also has an on/off button 76 . When the on/off button 76 is activated the liquid crystal display housing member 18 slides out from the camera base 16 as illustrated in FIG. 9 . As in the first embodiment, the liquid crystal display housing member 18 covers and protects the lense 26 when the camera is in its non-operational mode. When the liquid crystal display housing member 18 is fully extended, as illustrated in FIG. 10 , the camera automatically starts recording and the liquid crystal display 36 is activated.
This embodiment has a remote port hookup 86 on the camera base 16 . A remote pad 78 having a zoom in the button 80 , a zoom out button 82 and an on/off button 84 can be attached to the remote port hookup 86 , the remote pad 78 becomes operational. This design allows the operator to place the camera controls in a convenient location for optimal efficiency, like the forearm 100 of a firearm or the riser 104 of a bow.
Although, there are equivalent ways, common in the art, to control the movement of the liquid crystal display housing member 18 , my preferred method is illustrated in FIG. 11 . The liquid crystal display housing motor 81 has threaded shaft 83 . The liquid crystal display housing member 18 has an internally threaded insert 85 that is threadably engaged with the threaded shaft 83 of the liquid crystal display housing motor 81 . An “H” switch circuit controls the direction that the threaded shaft rotates. When the threaded shaft 83 rotates clockwise the liquid crystal display housing member 18 sides into the camera base 16 . When the threaded shaft 83 rotates counter clockwise the liquid crystal display housing member 18 sides out of the camera base 16 . The use of this system is common in the art and an example of an “H” switch circuit can be found in U.S. Pat. No. 4,454,454 issued to Valentine entitled Mosfet “H” Switch Circuit for a DC motor. In addition, a block diagram of the system is illustrated in FIG. 12 .
A bracket that mounts to a weapon is illustrated in FIG. 13 . The upper mount member 91 has a number of screw holes 97 . The lower mount member 92 has the same number of threaded screw holes 99 . A foam rubber insert 93 covers the inner surface of the upper mount member 91 and the inner surface of the lower mount member 92 to protect the surface of what the mounting bracket is being mounted to. The bracket mounted to a barrel 98 of a firearm is illustrated in FIG. 14 . The upper mount member 91 is placed over the top of the barrel 98 of the firearm. The lower mount member 92 is placed under the barrel 98 . The screw holes 97 in the upper mount member 91 are then lined up with the threaded screw holes 99 in the lower mount member 92 , securing the mounting bracket to the weapon. In addition, the thickness of the foam rubber insert 93 can be changed to accommodate different size barrels 98 .
As FIG. 14 . illustrates, the video camera is attached to the mounting bracket by sliding the camera mount member 14 into the track of the lower mount member 92 . When the camera mount member 14 is positioned far enough into the track of the lower mount member 92 it is locked into place. This is to ensure that the camera will not inadvertently fall off the weapon. The mechanism that locks the camera into place is illustrated in FIGS. 15 , 16 & 17 . A pair of biasing springs 107 are inserted into cavities 111 in the camera mount member 14 . A pair of fastening buttons 105 are then inserted into the cavities 111 engaging the biasing springs 107 . The fastening buttons 105 are held in place by a pair of camera mount member plates 103 . The camera mount member plates 103 have circular holes that allow the fastening buttons 105 to protrude through them from the force of the biasing spring 107 . The camera mount member plates 103 are secured by the camera mount plate screws 101 being screwed into the threaded holes 109 in the camera mount member 14 .
A pair of release push buttons 115 are inserted into the push button cavities 116 in the lower mount member 92 . The release push buttons 115 are held in place by the mount member plates 114 . The mount member plates 114 are secured to the lower mount member 92 by the mount member plates screws 113 being screwed into the threaded screw holes 117 . The mount member plates 114 have circular holes in them that are large enough for the fastening buttons 105 to fit through.
FIG. 16 illustrates how the camera mount member 14 locks into place with the lower mount member 92 . As the camera mount member 14 slides along the track in the lower mount member 92 , the biasing springs 107 assert an outward pressure on the fasting buttons 105 . When the fasting buttons 105 encounter the holes in the mount member plates 114 they are forced into them. This action locks the video camera on the mount system. To remove the camera the operator simply presses in on the release push buttons 115 . This action forces the fastening buttons 105 out of the holes in the mount member plates 114 . This illustrated in FIG. 17 . The camera will then slide off the mount effortlessly. Having this simple method of removing the camera is important to the invention because it allows, without undue delay, the use of the camera without it being attached to a weapon.
The first embodiment of the video camera mounted to the barrel 98 of a firearm is illustrated in FIG. 18 . The firearm is shown having a barrel 98 and a forearm 100 . One reason for the cylindrical design of the camera body is so it is natural for the operator to use the body of the video camera as he or she would the forearm 100 of the firearm. If the operator does this, his or her thumb will be in a natural position to operate the zoom in button 22 and the zoom out button 24 with little effort or movement. In addition, the remote pad 78 in my second embodiment can be attached to the forearm 100 of the firearm by Velcro, or by some similar fashion, for ease of operation.
The first embodiment of my invention mounted to a bow is illustrated in FIG. 19 . The bow is shown having a riser 104 , a flexible bow element 106 , a cable guard 110 , bow string 112 , an internally threaded metal insert 108 is shown having the counter weight bar 102 threadably attached. A counter weight bar 102 is used to stabilize the bow when the bow string 112 is drawn back. The mounting bracket is attached to the counter weight bar 102 the same way it is attached to the barrel 98 of a firearm. In addition, the thickness of the foam rubber insert 93 in the mounting bracket can be changed to accommodate the diameter of the counter weight bar 102 . Moreover, the remote pad 78 in my second embodiment can be attached to the riser 104 of the bow by Velcro, or by some similar fashion, for ease of operation.
I have designed a game hunters video camera that overcomes the limitations of a prior art. My video camera is designed for hunting situations where the ease of the use and ability to function properly and quickly in extreme situations and weather conditions are paramount to filming the hunting experience. Although, alternative embodiments and modifications are contemplated, I have disclosed my preferred embodiments. In addition, changes and alterations may be made to my preferred embodiments without departing from the spirit of and scope of my invention, as defined by the following claims.
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A camera having a lens and display. The camera also includes a main camera body and a display housing. The display housing has a front side and a back side. The display is encased in the back side of the display housing. The main camera body has a front end and a back end. The display housing is movably connected to the main camera body. The camera lens is of a given diameter and is encased in the front end of the main camera body. The display housing has first and second positions relative to the camera lens. In the first position, the display housing covers the lens and in the second position, the lens is exposed.
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This invention generally relates to the use of liquid smoke manufactured by a fast pyrolysis method for processing, flavoring and coloring, meat, fish, poultry and other food products.
BACKGROUND OF THE INVENTION
Use of liquid smoke solutions as a replacement for smoking by direct contact with smoke produced from wood has become a standard industry practice. When applied to the surface of meats and other proteinaceous foodstuffs, liquid smoke will not only give the item a characteristic smoke flavor, but will react with the proteins to produce the dark color typical of smoked foods.
One such liquid smoke preparation used commercially, for surface applications is the aqueous smoke flavoring described in Hollenbeck U.S. Pat. No. 3,106,473. This product is produced by partial combustion of hardwood sawdust with limited access to air, followed by subsequent solvation of the desirable smoke constituents into water. A heavy, water insoluble phase which contains tar, polymers, polycyclic aromatic hydrocarbons including benzo[a]pyrene, waxes and other undesirable products unsuitable for use in food applications is discarded.
Smoke is a complex and variable mixture of chemicals which are produced from pyrolysis reactions and includes vaporous compounds which are normally liquid at room temperature. Pyrolysis is a general term for the thermal decomposition of any organic material (i.e. wood, plants, fossil fuels etc.) and can occur during a combustion process or in the absence of combustion. In the former, the oxidation or burning of a portion of the organic matter provides the heat required to vaporize and decompose the remainder. In the absence of combustion, heat must be supplied indirectly from some other source (i.e. radiation, a solid or gaseous heat carrier, or conduction through reactor walls, etc.).
Pyrolysis produces liquids (i.e. condensable vapors), gases (non-condensables) and solids (char and ash) in varying proportions depending upon reaction conditions. The liquids can be further sub-divided into water soluble organics and non-water soluble tars. It is known that the desirable active ingredients for smoke flavoring are among the water soluble condensable vapors (liquids).
Currently liquid smoke is made using conventional pyrolysis which is characterized by relatively slow thermal reactions occurring at moderate temperatures. In the commercial processes, the wood feedstock is dried and ground to sawdust and fed to a reactor system. A typical average reactor temperature is approximately 420° C. Depending on the method of heating, the temperature gradient in the reactor may be from 600° C. at the heater to 250° C. at the bulk wood surface. Residence times of solids (wood/char) and vapors are approximately 10 minutes and 1 minute respectively.
Conventional pyrolysis produces liquid, gas and char yields which are typically 35, 35 and 30% by mass of the wood feedstock, respectively. Since the water insoluble constituents are between 50 and 65% of the total liquids derived from the wood content, the net yield of raw liquid smoke is relatively low (i.e. 12 to 20% of the wood feedstock).
The pyrolysis products are often passed through a water bath or scrubber. The gaseous products pass through the water bath. The solids and water insoluble tars precipitate out of the water with the water soluble organics are collected in the water as liquid smoke.
While there are hundreds of distinct chemical species present in liquid smoke, liquid smoke products have been characterized by three classes of chemicals according to distinct functional groups. The three classes are (1) acids, (2) carbonyls and (3) phenols
This functional definition is useful since phenols are the primary flavoring compounds while carbonyls are responsible mainly for coloration and acids serve as a preservative. Acids and carbonyls also make a secondary contribution to flavor and they enhance the surface characteristics of the meat products.
Acids are measured as titratable acidity calculated as acetic acid. Phenols are calculated as 2,6-dimethoxyphenol. The procedure for determining phenols is a modified Gibbs method. Carbonyls are calculated as 2-butanone. The procedure for determining carbonyls is a modified Lappan-Clark method. The procedures for determining carbonyls and phenols are described in U.S. Pat. No. 4,431,032 the contents of which are incorporated herein by reference.
A further measurement that is used to characterize liquid smoke is the browning index. The browning index is used in the smoke flavoring industry to measure the browning performance of a liquid. The browning index is a colormetric technique that measures the extent to which the carbonyls react with glycine. The browning index is determined from the difference between the adsorption at 400 nanometers of the glycine reacted solution and a control sample.
The application of liquid smoke solutions to meat and other food products can be carried out in a number of ways. Where the characteristic smoked color is desired, spraying or dipping can be done on individual items in a batch or continuous mode. Where large batches are to be processed an atomized cloud of liquid smoke can be employed. Alternatively, sausages and hams may be processed in casings into which liquid smoke solutions have been incorporated. In any case, where surface color is the primary effect which is sought, a measure of total carbonyls is used to judge the quantity of smoke required. These compounds react with the available amino groups of proteins at the surface to form the smoked color. The concentration of a specific carbonyl, hydroxyacetaldehyde, is also a good indicator of the color forming potential of liquid smoke.
Prior methods of producing liquid smoke suffer from relatively low yields of desirable products and relatively high yields of the undesirable by-products. In addition the levels of benzo[a]pyrene, a known carcinogen, is relatively high, requiring subsequent dilution of the collected condensable vapors with water to separate out these compounds.
The requirement to dilute the collected condensables to limit the level of benzo[a]pyrene below 0.5 ppb prevents the production of liquid smoke having a total acid content above 13% or a browning index above 13.0 without subsequent concentration.
Recently new methods have been developed for the rapid thermal processing of carbonaceous feedstocks. These methods have been called fast or flash pyrolysis.
Fast or flash pyrolysis of wood or cellulose is a method of imparting a high heating rate to the wood for a very short time and then rapidly quenching the pyrolysis products to a temperature below 350° C. The heating rate for fast pyrolysis is greater than 1000° C. per second and vapor residence times are below 2.0 second. While fast pyrolysis methods are known, the research and development in this area has concentrated on producing liquid and gaseous fuels, and on optimizing the production of high energy value fuels.
One object of this invention is to provide a method of using the water soluble products from fast pyrolysis to produce liquid smoke in place of conventional liquid smoke to achieve greater yields and higher concentrations of desirable product and lower yields of gaseous and solid by-products, resulting in greater efficiency and resulting cost savings.
Specifically fast or flash pyrolysis results in higher hydroxyacetaldehyde and other carbonyl yields and lower char, benzo[a]pyrene and gas yields. The higher carbonyl yields effects a higher browning index.
Further cost efficiencies results from a faster rate of the reaction in fast or flash pyrolysis which permits greater processing efficiencies in that smaller reactor volumes are required to process a given quantity of feedstock.
Another object of this invention is to provide a method for preparing a smoke colored and smoke flavored food product by treatment of the said food products with the aforementioned liquid smoke solution.
Other objects and advantages of the invention will become apparent from the ensuing disclosure and claims.
SUMMARY OF THE INVENTION
Accordingly, the invention herein comprises a method of manufacturing and optimizing the liquid pyrolysis products from a fast or flash pyrolysis method to produce a liquid that is very suitable for use as liquid smoke. The liquid smoke of the invention herein is achieved in high yields, i.e. with low char and tar formation. It contains less than 1.0 ppb of benzo[a]pyrene, and preferably less than 0.5 ppb of benso[a]pyrene, a known carcinogen, and a higher coloring ability than liquid smoke produced by traditional methods.
Furthermore, these solutions will impart the desired smoked color to meat with milder, less smoky flavor than would be expected from slow pyrolysis liquid smoke solutions. The high ratio of carbonyls (the reactive color forming compounds) to phenols (the flavoring compounds) is indicative of this relatively high coloring ability, low flavor nature of fast pyrolysis liquid smoke solutions.
In accordance with the present invention there is provided a process of making an aqueous wood smoke flavoured solution for use in foodstuffs comprising:
(1) heating in an oxygen starved atmosphere ground wood or cellulose to between 400° C. and 650° C. within 1.0 second;
(2) maintaining the said wood or cellulose and the primary pyrolysis vapors between 400° C. and 650° C. for between 0.03 and 2.0 seconds and preferably between 0.03 and 0.60 seconds.
(3) reducing the temperature of the pyrolysis products to below 350° C. within 0.6 seconds;
(4) separating and collecting the water soluble liquid products;
(5) diluting the said water soluble liquid products with water to achieve a partial phase separation and to reduce the benzo[a]pyrene concentration to less than 1.0 ppb and preferably to less than 0.5 ppb.
In accordance with a further aspect of this invention there is provided a process of flavoring and coloring an edible food by contacting the food with an aqueous wood smoke flavored solution produced by fast or flash pyrolysis.
In accordance with another aspect of the present invention there is provided a process of producing a liquid smoke solution comprising:
(1) collecting the liquid condensate product obtained by fast or flash pyrolysis of ground wood or cellulose in an oxygen starved atmosphere, without the addition of water;
(2) combining one part of the pyrolysis liquid condensate with 0.25 to 25 parts by weight of water and then separating the resulting non-adqueous phase from the aqueous phase constituting the desired liquid smoke solution.
In accordance with yet another aspect there is provided a process in which sufficient water is added to produce a liquid smoke solution wherein the ratio of the browning index to the phenol concentration is greater than 8.9 to 1% carbonyls.
Since fast or flash pyrolysis liquids are produced without the addition of water, unlike conventionally produced liquid smoke solutions, they consist of a single phase. Due to the extremely fast heating rate and short residence time, these solutions are inherently low in benzo[a]pyrene content however the levels, while at least an order of magnitude less than the levels produced by conventional liquid smoke, are still too high for consumption in many countries. Therefore, to reduce the benzo[a]pyrene to less than 0.5 ppb, an addition of water to cause a separation of phases is necessary. Accordingly, the invention comprises the comestible, aqueous soluble fraction of fast pyrolysis products.
The use of this particular liquid in the liquid smoke flavoring industry results in a much improved liquid smoke that avoids a number of the shortcomings of the prior art, while at the same time, resulting in increased yields and a better quality product.
Using fast or flash pyrolysis methods, up to 80% yield of liquid products can be realized. Given the right operating parameters, the char yields will be around 6% with the remaining portion of the products being gaseous in nature. The char yields can be reduced to below 1% if desired.
Liquid smoke manufactured by fast pyrolysis methods exhibits increased total carbonyls, phenols and acids, and has a much improved browning index.
The total water soluble carbonyls, phenols, acids and browning index of a representative sample of commercial liquid smoke and products from two fast pyrolysis methods are set out in Table 1 below.
TABLE 1______________________________________ANALYSIS OF WATER SOLUBLE LIQUIDSYields From Wood Browning Total Total Total Index Units/Sample Carbonyls Phenols Acids 100 g boneSource (% w/w) (% w/w) (% w/w) dry wood______________________________________1. Fluidized 22.2 1.6 6.9 2877 Bed (500° C. 0.5 s)2. Rapid 20.7-26.0 1.3-2.0 6.2-7.3 2390-3400 Thermal Processing (600° C. 0.2 s)3. Commer- cial 6.0 0.7 5.3 518 Liquid Smoke______________________________________ % w/w % by weight of product yield from bone dry wood feedstock as measured in water soluble fraction
As can be noted from Table 1, the yield of carbonyls is approximately 3 times better using liquids manufactured by a fast pyrolysis method over commercial liquid smoke, while the yield of phenols has more than doubled; the yield of acids has been improved, and the browning index is about 6 times better.
The level of benzo(a)pyrene, in the fast pyrolysis liquids before dilution and phase separation is at least an order of magnitude lower than liquids produced by known commercial process. This lower level of benzo(a)pyrene allows a more concentrated product to be produced. The total condensate from conventional pyrolysis contains approximately 750 ppb of benzo(a)pyrene.
The level of benzo(a)pyrene in the total condensate from fast pyrolysis is between 5 and 50 ppb.
With fast pyrolysis, after dilution and phase separation, the ratio of carbonyls to phenols is higher which is indicative of the high browning potential relative to the amount of flavor. In addition, the undesirable by-product yields of gas and solid char are lower and the corresponding disposal costs are lower.
Unconcentrated commercial liquid smoke has a browning index between 3.0 to 13. While methods are available for concentrating liquid smoke to achieve a browning index of up to 25, unconcentrated liquid smoke has a practical upper limit of about 13 as the benzo(a)pyrene levels become excessive if the liquid smoke is permitted to continue to concentrate above this level in the water collection baths.
Through the use of fast pyrolysis methods browning indexes of up to 45 can be achieved without using any concentration steps and with levels of benzo(a)pyrenes below 0.5 ppb.
The presence of hydroxyacetaldehyde is useful as an index to rate the value of the liquid for smoke coloring applications. The yield of this compound by fast or flash pyrolysis methods increases with a decrease in temperature from 900° to about 500° C. and a decrease in residence time. Yields of hydroxyacetaldehyde in excess of 8% by mass can be obtained at reaction temperatures of 550° or 600° C. and 100 millisecond vapor residence time.
The yield of hydroxyacetaldehyde is much greater from fast pyrolysis methods. A comprison of yields of hydroxyacetaldehyde from two fast pyrolysis methods and commercial liquid smoke is set out in Table 2. As can be noted, yields up to about 4 times higher are achieved using fast pyrolysis. Hydroxyacetaldehyde is one of the predominant carbonyls in wood pyrolysis liquids and is therefore used as an index to assess a liquid's potential for liquid smoke applications.
TABLE 2______________________________________CHEMICAL ANALYSIS OF THE PYROLYSIS LIQUIDS(Hydroxyacetaldehyde Yields)Sample HydroxyacetaldehydeSource Yield (% w/w)______________________________________1. Fluidized Bed 7.5 to 8.5 (450 to 550° C., 0.5 s)2. Rapid Thermal 7.0 to 8.0 Processing (550 to 700° C., 0.2 s)3. Commercial Liquid less than 2% Smoke______________________________________
Hydroxyacetaldehyde (glycoaldehyde) and acetol (1-Hydroxy-2-Propanone) are the two predominant carbonyls in pyrolysis liquids. Hydroxyacetaldehyde is much more reactive in terms of browning and its presence is an excellent indication of the browning ability of the liquid. Acetol is a poor browner. The ratio of hydroxyacetaldehyde to acetol can therefore be used as an index of the effectiveness of the carbonyls in the liquids with respect to browning ability.
Analyses show that the ratio of hydroxy acetaldehyde to acetol in conventional liquid smoke is typically less than 1.0. However, the average ratio (4 samples) of hydroxyacetaldehyde/acetol in fast pyrolysis liquids is about 6 (5.9) while the maximum measured ratio is 7.2. In effect, not only are more carbonyls produced during fast pyrolysis (i.e. higher yields), but the carbonyls that are produced are more effective browning agents.
The parameters that should be optimized in any fast pyrolysis method to produce a suitable liquid product for use as liquid smoke, include:
(1) high heating rates of the wood feedstock (greater than 1,000° C. per sec.);
(2) a vapor residence time (i.e. the average time that the gas/vapor phase remains in the reactor) greater than 0.15 sec. and less than 1.0 sec. and preferably less than 0.6 sec.;
(3) isothermal reaction reactor temperatures between 400° and 800° C.; and
(4) quenching of the liquid/vapor product to a temperature of less than 300° C. in less than 0.6 sec. in order to preserve the high liquid yields.
When vacuum pyrolysis apparatus is used, the heating rate of the wood or cellulose is much slower than with rapid thermal processing apparatus or with a fluidized bed reactor. Secondary pyrolysis reactions however are reduced by quickly removing and cooling the primary pyrolysis vapours. As such, the fast heating rate is not essential as long as the secondary reactions are limited.
The major components of the fast pyrolysis process are designed to achieve a very high temperature within a minimum amount of time as well as having a relatively short residence time at that temperature to effect pyrolysis of the wood or cellulose. This short residence time at high temperature has been achieved by a number of systems. One method is a vacuum pyrolysis process that is based on the principle that primary products can be withdrawn from the reactor under vacuum conditions before they have a chance to react further and produce secondary pyrolysis products. This method has been described in Fundamentals of Thermo-Chemical Biomass Conversion R. P. Overend et al. (editors) Elsevier publishers, (1985) in an article entitled "Pyrolysis under Vacuum of Aspen Poplar" by Christian Roy, Bruno de Caumia, Dominique Brouillard and Hughes Menard, the contents of which are incorporated herein by reference. The solid wood feedstock remains in the reactor until completely reacted. Total liquid yields of between 68 and 74% by mass of the total wood feedstock have been reported at reaction temperatures of 450° C. and a solid heating rate of 10° C./min. and a residence time of up to 2 seconds. At a vapor residence time of about 2.0 seconds the char yields were between 16 and 20% by mass of the wood feed material.
A second method for obtaining fast pyrolysis is "flash" pyrolysis, using a fluidized bed reactor system operating at temperatures between 400° and 650° C. Total liquid yields of between 60 and 70% of the wood feed stock have been obtained with an average vapor residence time of 0.5 sec. The char yield was typically between 10 and 20% of the wood mass. Residence times of up to 3.0 seconds can be achieved. (See "Production of Liquids from Biomass by Continuous Fast Pyrolysis" in Bioenergy 84 vol. 3, Biomass Conversion; D. S. Scott, and J. Piskorz the contents of which are incorporated herein by reference).
A third method is a fast pyrolysis process which uses hot particulate solids and/or inert gases to rapidly transfer heat to the carbonaceous feedstocks in a reactor system (Rapid Thermal Processing). This results in very high gas or liquid yields from biomass depending upon the reactor conditions. Char yields are from 0 to 6% depending upon the feedstock, reactor temperature and residence time. Maximum gas yields are 90% of the feed stock mass at 900° C. and maximum liquid yields are 85% of the feed stock mass at 600°-650° C. This apparatus can be operated between 350° C. and 1000° C. with residence times between 0.030 seconds to 3.0 seconds.
Each of these fast pyrolysis methods offer much improved yields an improved quality of the liquid product and gaseous products where applicable, over conventional pyrolysis systems.
BRIEF DESCRIPTION OF THE DRAWINGS
Details of embodiments of the invention are described by reference to the accompanying drawings in which:
FIG. 1 is a schematic representation of one fast pyrolysis flow system known as rapid thermal processing.
FIG. 2 is a top plan view of the reactor of the pyrolysis apparatus of FIG. 1.
FIG. 3 is a section on the line III--III of FIG. 2.
FIG. 4 is a graph of product yield by mass percent as a function of residence time in milliseconds.
FIG. 5 is a graph of yield of hydroxyacetaldehyde as a function of reactor temperature.
FIG. 6 is a graph of hydroxyacetaldehyde yield as a function of residence time at different temperatures.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In the following descriptions the corresponding elements as shown in each figure of the drawings are given the same reference number.
While in the accompanying drawings and description, reference is made to the Rapid Thermal Processing, similar products can be achieved using the vacuum and flash pyrolysis systems as well as other systems that result in a high temperature with a limited residence time.
The major components of the rapid thermal process are illustrated in FIG. 1. Rapid mixing and heat transfer are carried out in two vessels. The first vessel (1) the thermal mixer allows heat to be transferred to the wood from hot particulate solids or inert gas which can consist of gaseous nitrogen, suspended particulate solids, or a combination of the two. The second vessel (2), the quencher, allows fast quenching of the products to reduce secondary reactions of the initial pyrolysis products.
As shown in FIGS. 2 and 3 the thermal mixer (1) has opposing converging inlets (3) for the solid heat carrier. This system effectively destroys the radial momentum of the heat carrier causing severe turbulence. Powdered wood feedstocks are then injected from the top of the thermal mixer (1) through a cooled tube (4) into the turbulent region where mixing occurs within 30 milliseconds.
After heating and mixing occurs, the wood or cellulose and the primary pyrolysis vapours are maintained at the reaction temperature for between 0.03 and 2.0 seconds depending upon the desired products. The primary pyrolysis vapours are produced as soon as the wood or cellulose is sufficiently heated to start the pyrolysis reactions.
The hot gaseous product is rapidly cooled (i.e. less than 30 milliseconds) by the injection of a single tangential stream of cryogenic nitrogen (5). Mechanical table feeders are used to supply wood to the reactor system. The solids pass from sealed hoppers (6) (which have a sufficient inventory of wood or particulate solids) through a double funnel system and are thereby metered onto a rotating table. Two fixed armatures sit near the surface of the rotating table and plough the solids off the outer circumference. From the table, the solids then fall into a conical chamber where they are picked up and carried into the transport line by nitrogen carrier gas. The overall range of the feed rate of biomass or particulate solids is controlled by setting the gap between the lower funnel and the table. Fine control is exercised by the rotation speed of the table.
When particulate solids are required to supply the process heat, the feeders (7) send hot particulate solids through a non-mechanical high temperature valve which operates at the reaction temperature. These hot solids are then sent on to the thermal mixer (1).
The solid particulate carbonaceous feedstock (or atomized carbonaceous liquids) is then injected axially into the reactor (1) through a water or air cooled tube (4) into the turbulent region where effective mixing and rapid heating to at least 400° C. occurs within 0.10 seconds, and preferably within 0.03 seconds.
The fast pyrolysis of wood is initiated in the thermal mixer (1) and continues in a transport reactor (9). The transport reactor is a length of pipe which is housed in an electrical oven (10). The mixture of hot gases and biomass passes from the thermal mixer (1), through the transport reactor (9), to the quencher (2) and to the solids separator (23). With the manipulation of the reactor volume and by manipulating heat carrier/biomass flow-rates, the residence time can be varied between 30 ms and 3.0 seconds. Reactor temperatures can be set in the range of 400° to 1000° C. Preferable reactor temperatures are between 400° to 800° C. and more preferably between 500° to 600° C. The heating rate that can be achieved with this apparatus is over 10,000° C. per second.
An efficient cyclonic condensor (25) is used to increase the yield of recovered liquid products. In addition an electrostatic precipitator (24) can be integrated into a downstream gas line to recover additional liquid products.
The wood feedstock can be any suitable wood product, but is preferably red maple. The feedstock should be ground to a fine 100 to 500 μm powder and then dried prior to use as the pyrolysis feedstock.
After collection of the condensates, water is added to cause phase separation to reduce benzo(a)pyrene, and tars. The amount of water added beyond that necessary to achieve effective phase separation is a matter of choice. The more water added, the greater the precipitation of higher molecular weight components. Water can be added beyond the phase separation to any desired degree to achieve a desired browning index level.
In application to wieners, solutions with browning indexes down to about 3 are useful in producing a desirable, smoke flavored and colored product. In some markets where browner, heavily smoked products are preferred, solutions of aqueous smoke flavorings with browning indexes of at least 20 are routinely used.
Where atomization is the preferred method of application, it is sometimes difficult to obtain sufficient smoke coloration on meats. In these situations smoke flavoring solutions with browning indexes ranging up to 30 are of use. The amount of water added to the condensates of the instant invention to produce a solution suitable for application to meats or other foods is a function of the effect sought by the processor.
Commercially available liquid smoke has browning indexes ranging from a 3 browning index minimum with a practical upper limit of about 30. This upper limit is a result of the limitations of prior methods of producing lquid smoke. The prior methods generally collect the water soluble condensation in a water bath and it is desired to keep the browning index below 13 to reduce the benzo(a)pyrene concentration. A browning index of above 13 is then achieved by concentration. In the result it becomes increasingly difficult and expensive to produce the liquid smoke above a browning index of 13. The difficulty and expense of concentration sets a practical upper limit of 30 as opposed to a limit beyond which solutions are not useful. On the contrary, if solutions were readily available with browning indexes of 30 or more they would be of particular use in atomization or as a starting material for application to casings as in U.S. Pat. No. 4,504,501. By adding little or no water to condensates of the instant invention, very high browning index sxolutions can be produced without need or expense of further concentration.
EXAMPLE 1
A general summary of the results of fast pyrolysis conducted using rapid thermal process apparatus between 650° and 800° C. using red maple feedstock and nitrogen as the heat carrier using the rapid thermal apparatus is given in Table 3. The apparatus used for these results was rated at 300 g of feedstock per hour. The yields for char and gas represent direct measurements and those for the liquids are by difference. These liquid yield values, however, are very close to the actual liquid yields as verified by the mass balance closures. All mass percent yields in Table 3 are expressed on a bone dry feedstock basis. It is clear from the results, that the char yields are significantly lower, and the liquid yields are significantly higher than the corresponding yields from conventional slow pyrolysis processes.
TABLE 3__________________________________________________________________________SUMMARY OF THE RED MAPLE PYROLYSIS MASS BALANCEEXPERIMENTS Res Condenser Remaining TotalRun Temp Time Gas Yield Liquids Liquids Char Recoverynumber(C.) (ms) (%) (%) (%) (%) (%)__________________________________________________________________________RA-21650 234 24.18 -- 70.52 5.97 100.67RA-22650 217 22.87 -- 67.89 5.96 96.72RA-24650 392 23.69 22.18 42.00 7.79 95.67RA-25650 194 19.83 19.69 45.75 9.69 94.96RA-26650 1052 33.47 31.34 27.51 6.61 98.92RA-1 700 110 29.18 16.91 45.65 3.50 95.24RA-2 700 152 31.95 17.03 38.74 3.93 91.65RA-3 700 241 35.64 15.18 43.01 4.18 98.01RA-5 700 338 40.87 12.87 41.32 2.64 97.71RA-6 700 339 43.60 18.05 32.2 2.62 96.48RA-7 700 151 39.56 16.47 40.29 2.29 98.62RA-8 700 69 25.62 19.89 48.32 4.21 98.04RA-9 700 226 30.98 16.10 44.39 4.79 96.30RA-19700 68 21.79 -- 72.11 1.42 95.32RA-27700 718 43.73 19.73 28.91 3.88 96.24RA-10750 351 53.88 13.76 15.48 3.75 86.88RA-11750 150 43.25 14.25 39.38 3.00 99.88RA-12750 74 39.29 17.85 36.92 2.75 96.81RA-13750 71 39.55 13.84 40.20 2.16 95.75RA-14750 153 43.14 15.07 33.98 3.11 95.17RA-15750 348 54.02 19.0 19.36 4.30 96.68RA-16800 329 58.22 9.80 31.59 4.03 103.6RA-17800 160 56.06 -- 37.17 3.72 96.95RA-18800 76 41.81 -- 52.19 1.68 95.69__________________________________________________________________________ *Note: -- Where condenser liquids are not shown (value not recorded), remaining liquids represents entire liquid sample These results are on an "as fed" basis.
EXAMPLE 2
Rapid Thermal Process Apparatus Operation and Results
Operating Parameters
Experiments were conducted using poplar wood ground to about 300 um (microns).
Wood moisture was about 1% (wet basis).
Wood was fed at a rate in the range of 3 to 5 kg/h.
Reaction temperatures were in the range of 400° to 650° C.
Vapor residence times were typically in the range of 600 to 1200 milliseconds (ms).
The heat carrier consisted of Ottawa silica sand with a mean particle size of about 150 microns and transported by inert nitrogen gas.
Equipment and Operating Procedure:
Rapid thermal processing apparatus of the type shown in FIGS. 1, 2 and 3, using hot particulate sand as the heat source was employed to produce liquid smoke. The apparatus is nominally rated at 5 kilograms of feedstock per hour. Three heat carrier feeders are used to heat up the sand heat carrier and deliver it to the transport lines. Each feeder is about 1.2 meters long and 150 mm outside diameter, and can hold 30 kg silica sand. The maximum feed rate is about 60 kg per hour (for each feeder) and the maximum temperature of the heat carrier is 1100° C. Feeder control is accomplished via a sparger tube and non-mechanical, high temperature "J" valve.
The poplar wood is air dried, milled and classified to a mean particle size of about 300 um. It is then oven dried prior to loading into the biomass feeder. The biomass feeder has an inventory of about 4 kg. Feed rates can be varied from 0 to about 10 kg per hour, and are independent of the transport gas flow rate and the solid carrier flow rate.
The wood feed material is delivered from the "biomass feeder" to the top of the reactor where it is injected into the cloud of turbulent hot solids. Extremely rapid heating of the feed material is achieved as the feedstock and hot sand particles are quickly and thoroughly mixed. After the fast, intimate mixing is complete, the feedstock and solid heat carrier pass through a tubular transport react whose length is adjusted to control the processing residence time. The reactor system consists of a rapid thermal mixer and two lengths of transport reactor. Each of these components is housed in its own oven with independent temperature control. Rapid mixing of the feedstocks with the solid heat carrier (i.e. sand) placed in the rapid thermal mixer is effected, and chemical reactions are then allowed to proceed in the transport reactor sections. The first reactor is 1.2 m in length while the second is 0.6 m. The reactor system components are constructed of Sch 40 Inconel 601 (40 mm I.D./1.5" nominal).
The products are rapidly cooled in the transfer line after the hot solids (char/sand) are removed in a solids "catch pot" or drop-out vessel. Additional cooling is carried out in the primary (water-cooled) and secondary (dry ice/acetone-cooled) condensers, where condensation of vapours and recovery of liquids also occur. The solids catch pot is an inertial separator constructed of stainless steel which can hold about 100 kg of hot solids. Separation of the gases from the solids is based on the lower momentum of the gas/vapour product (compared to the hot sand) which can change direction more readily than the solids, and escape into the transfer line to be quenched directly with nitrogen gas.
The primary condenser is a water-jacketed carbon steel pipe (having both an inner and outer water-jacket) which is lined with a chemical resistant paint. The cooling water enters at about 19° C. and cools the product to about 35° C.
The secondary condenser is also a lined, carbon-steel pipe which is not jacketed but sits directly in an insulated acetone/dry ice bath. It has a tangential gas/vapour inlet which forces the products to the condenser wall where efficient heat transfer can occur. The secondary unit yields a gas exit temperature of about -5° C.
Parallel filters are used to collect persistent aerosols, and the clean gas is then directed through an orifice meter to quantify the flow for mass balance closure. A fractional quantity of the product gas is continuously "bled" from the main stream to a gas sample bag for subsequent analyses. The three parallel filters are contructed of stainless steel, have a pore size of 0.5 microns and are housed in a single filter vessel. Each of these units are about 50 mm in diameter (outside) and about 0.5 mm long.
After a run, the condenser, filters and transport lines are washed with acetone, the solution is filtered, and the acetone is evaporated under vacuum to yield the liquid product. Char is determined by ashing several representative samples of the char/sand mixture which is recovered from the solids separator. Gases are analyzed by standard gas chromatography techniques.
TABLE 4______________________________________SUMMARY OF POPLAR WOOD PYROLYSISMASS BALANCE EXPERIMENTS RES. PRODUCT YIELDSRUN TEMP. TIME (% of wood feed)NUMBER (°C.) (ms) Gas Liquid Char______________________________________9 660 800 32.9 60.3 6.810 525 835 14.9 78.0 7.011 465 1215 7.0 86.0 7.012 590 960 20.5 71.8 7.7______________________________________
EXAMPLE 3
Fluidized Bed Operation and Results
Fluidized Bed Operation
Operating Parameters:
Experiments were conducted using poplar wood ground to -595 microns (-30 mesh).
Wood moisture was about 6% (wet basis).
Wood was fed at a rate of 1 to 2.5 kg/h.
Reaction temperatures (in the bed) were in the range of 400° to 650° C.
Vapor residence times were typically in the range of 500 to 700 milliseconds (ms).
The fluidized bed consisted of Ottawa silica sand with a mean particle size of about 720 microns.
Recycled product gas (primarily CO, CO 2 and CH 4 ) was used to fluidize the sand and to transport the wood feedstock into the reactor.
Equipment and Operating Procedure:
Poplar wood (or other wood species, straw or peat) is air dried, milled and screened to -595 um particle size.
The prepared wood is conveyed from a hopper into a variable speed twin-screw feeder and discharged into a flow of recycled product gas. It is then conveyed into the fluidized bed reactor directly into the fluidized bed region.
The reactor bed consisted of highly spherical Ottawa silica sand with a mean particle size of about 720 um.
The fluidizing gas (primarily CO, CO 2 and CH 4 ) is preheated in the inlet line by electrical heaters and enters the bed through a porous stainless steel plate at a rate which is equivalent to 1.2 to 2 times the minimum fluidization velocity.
The reactor is wrapped with heating coils for supplemental heating.
Pyrolysis products and the recycle gases are swept from the top of the reactor into a cyclone where the dry char is removed from the gas/vapor phase. The gases and vapors are then passed to two condensers and on to a series of filters.
The first condenser is normally operated at 20° C. while the second is maintained at about 0° C.
The filter train consists of an in-line 5 um (micron) mesh screen followed by a filter vessel packed with glass wool.
After a run, the condensers are washed with acetone, the solution is filtered, and the acetone is evaporated under vacuum to yield the liquid product. The filters are weighed before and after an experiment and the contents are recovered if the quantity is significant.
Char is collected in the char pot (at the cyclone exit) and weighed.
Gases are analyzed by standard gas chromatography techniques.
TABLE 5______________________________________FLUIDIZED BED RESULTS:RAPID PYROLYSIS OF POPLAR WOOD RES. PRODUCT YIELDS TOTALTEMP. TIME (% of wood feed) RECOVERY(°C.) (ms) Gas Liquid + Char %______________________________________425 616 6.0 59.6 (55.9) 30.5 96450 689 8.6 61.1 (55.8) 25.5 95465 584 8.6 72.7 (67.2) 18.9 100500 550 12.5 75.1 (65.8) 12.2 100500 550 12.1 77.8 (71.2) 11.2 101500 600 11.9 70.1 (65.8) 13.2 95541 539 21.2 71.1 (63.7) 9.0 101541 539 19.1 69.8 (62.1) 9.7 99550 555 18.6 67.3 (62.0) 10.6 96625 520 36.7 44.4 (40.3) 7.8 99______________________________________ + The values in parentheses are total organic liquids (ie. moisturefree) The difference is moisture (water) in the liquid sample. Similar experiments have been conducted with maple and spruce with similar overal yields of char, gas and liquid.
As is apparent from the data in Tables 3, 4 and 5, the preferred operating temperature is at the lower ranges with a relatively short residence time of 300-600 milliseconds. However good yields are achieved throughout the operating range of the rapid thermal processing equipment and over a variety of residence times. As shown in FIG. 4 the shorter the residence time that can be achieved, the higher the yields of the preferred liquid product.
As noted above, the yield of hydroxyacetaldehyde is a good indication of the browning ability of the liquid smoke. Yields of this compound versus reactor temperature and residence time are set out in FIGS. 5 and 6. FIG. 5 is a graph of hydroxyacetaldehyde yields of the fast pyrolysis of wood against temperature.
FIG. 5 confirms that the optimum reaction temperatures are between 500° and 600° C. FIG. 6 also confirms that the optimum conditions are between 500° and 600° C. with a short residence time.
EXAMPLE 4
A sample of the fluidized bed reactor liquid pyrolysate referred to in Example 3 was diluted with water according to the following proportions. The water soluble fraction was separated and analyzed.
TABLE 6__________________________________________________________________________DILUTIONS OF FAST PYROLYSIS LIQUIDSweight %fastpyrolysisliquids in Browning Specific Benzo(a)totalAcids Phenols Carbonyls Index Gravity pyrenesolution% w/w % w/w % w/w Units @ 21° C. ppb__________________________________________________________________________100 10.5 5.50 32.5 49.0 1.245 19.085 9.1 3.75 29.2 46.8 1.201 14.080 8.7 3.31 26.6 45.6 1.182 3.670 7.9 2.42 21.4 35.8 1.148 0.565 7.5 2.10 20.2 33.8 1.120 0.560 6.5 1.65 17.5 31.5 1.112 0.540 4.1 0.820 10.3 18.2 1.065 0.520 2.8 0.430 5.4 12.2 1.028 0.510 1.3 0.230 4.9 5.6 1.011 0.5__________________________________________________________________________
These results are indicative of the advantage to adding sufficient water to cause enough phase separation to reduce the B(a)P content to less than 0.5 ppb. As can be seen from Tables 7 and 8 the resulting solutions have substantially higher carbonyl to phenol and browning index to phenol ratios than commercially available solutions produced by slow pyrolysis processes.
TABLE 7______________________________________RATIO OF CARBONYL AND BROWNINGINDEX TO PHENOLSWeight % offast pyrolysisliquids in Browning Carbonyls/ Browning index/total solution index phenols phenols______________________________________100 49.0 5.90 8.9185 46.8 7.79 12.580 45.6 8.04 13.870 35.8 8.84 14.865 33.8 9.62 16.160 31.5 10.6 19.140 18.2 12.6 22.2______________________________________
TABLE 8______________________________________AVERAGE OF TEN REPRESENTATIVE RATIOSFROM SLOW PYROLYSIS LIQUID SMOKE SOLUTIONSAcidConcentration Browning Carbonyls/ Browning index/% w/w index phenols phenols______________________________________11.5 9.8 6.47 5.766.2 5.3 7.78 6.17______________________________________
As seen in both tables 7 and 8 the ratios are higher in more dilute solutions. This is because the solubility of carbonyls is the same regardless of concentration while phenols are less soluble in more dilute solutions. Thus, the advantage of water addition to fast pyrolysis serves two purposes, to reduce phenols thereby reducing flavor while maintaining a high browning potential, and to reduce benzo(a)pyrene solubility to less than 0.5 ppb.
As can be seen by comparing Tables 7 and 8 at an equivalent browning index, the ratios of carbonyls to phenols and browning index to phenols is significantly greater with fast pyrolysis liquids than with conventional liquid smoke. The higher ratio with fast pyrolysis liquids results in a darker product at a given flavor level. This permits coloring of food with a less smoky flavor or alternatively to achieve a darker product at comparable flavor intensities.
The lowest browning index used for smoking meat is about 3.0. This browning index would be used for direct application to foodstuffs. Based on the above results the fast pyrolysis product could be diluted to about a 6.1% w/w solution and still have a browning index above 3.0.
EXAMPLE 5
Results of the Application of Fast Pyrolysis
Liquids to Wieners
1. Color/Browning Test Panel
About 2.5 lb. strands of skinless wieners obtained from Cher-Make Sausage Co. (Manitowoc, WI) were dipped for 60 seconds in the following:
A. Water (control)
B. A 10% (W/W) Solution of Fast Pyrolysis Liquids (Fluidized Bed)
The wieners were cooked to an internal temperature of 70° C. according to the following schedule:
43.3° C. for 10 minutes
60.0° C. for 45 minutes
71.1° C. for 25 minutes
82.2° C. until the internal temp. was 70° C.
After cooking, the wieners were placed in a 4.4° C. cooler overnight for subsequent evaluation and testing.
The following day, the wieners were peeled and a panel of 9 observers were asked to indicate which set had the most appealing brown color. All 9 indicated that sample B was noticeably browner than the water dipped control (and therefore more appealing).
The results are indicative of the ability of the aqueous solutions of fast pyrolysis liquids to react with meat surfaces to give a desirable smoked appearance.
2. Taste Comparison Test Panel
About 2.5 lb strands of skinless wieners obtained from Cher-Make Sausage Co. (Manitowoc, WI) were dipped for 60 seconds in the following:
A. A 10% (W/W) Solution of Fast Pyrolysis Liquids (Fluidized Bed)
B. A solution of slow pyrolysis liquid smoke made according to Hollenbeck, U.S. Pat. No. 3,106,473, the Browning Index of which was 3.9.
The wieners were cooked to an internal temperature of 70° C. according to the following schedule:
43.3° C. for 10 minutes
60.0° C. for 45 minutes
71.1° C. for 25 minutes
82.2° until the internal temp. was 70° C.
The following day, a panel of 9 were asked to asked to taste the wieners which had been peeled and warmed to 49° C. A triangular method (i.e. using 3 samples, two of the same treatment and one of the other) was used to determine whether the panelists could distinguish between the two treatments.
The results indicated that only one of the 9 panel members could determine a difference between aqueous solutions of fast pyrolysis liquids and conventional smoke flavorings when applied to the wieners. This is not statistically significant and the usefulness of the former for smoking meats is indicated.
The procedures for determining phenol and carbonyl content in liquid smoke are as follows:
Determination of Phenol and Carbonyl Content of Liquid Smoke
For sample preparation, all samples are filtered through Whatman No. 2 filter paper or equivalent, and refrigerated upon receipt or after preparation until the time of analysis to avoid possible polymerization. Distilled water is used for all dilutions. The samples are diluted with water in two steps, beginning with a 10 ml. quantity. In the first step the dilution is to a total volume of 200 ml., and in the second step 10 ml. of the first solution is further diluted to a total volume of 100 ml. For phenol determination, 5 ml. of the second solution is further diluted in a third step with distilled water to a total volume of 100 ml. For carbonyl determination, 1 ml. of the second solution is further diluted with carbonyl-free methanol to a total volume of 10 ml.
For the phenol determination, the reagents are:
1. Boric acid-potassium chloride buffer pH 8.3:
Dilute the indicated quantities of the solution to 1 liter with water.
0.4M Boric Acid-125 ml.
0.4M Potassium chloride-125 ml.
0.2M Sodium hydroxide-40 ml.
2. 0.6% NaOH
3. Color reagent: 2,6-dichloroquinonechlormide.
Stock solution: Dissolve 0.25 mg, in 30 ml. methanol and keep in refrigerator.
4. 2,6-Dimethoxyphenol (DMP) standards: Prepare solutions of 1 to 7 micrograms/ml. of DMP in water for standard curve.
This procedure for phenol determination is a modified Gibbs method based on the procedure described in Tucker, I. W. "Estimation of Phenols in Meat and Fat", JAOAC, XXV, 779 (1942). The reagents are mixed together in the following order:
1st-5 ml. of pH 8.3 buffer.
2nd-5 ml. of dilution of unknown diluted liquid smoke, or of standard 2,6-dimethoxyphenol solution, or 5 ml. of water for blank.
3rd-Adjust pH to 9.8 using 1 ml. of 0.6% NaOH.
4th-Dilute 1 ml. of color reagent stock solution to 15 ml. in water. Add 1 ml. of diluted color reagent. Prepared just before adding.
5th-Allow color to develop for exactly 25 minutes at room temperature.
6th-Determine absorbance at a wave length of 580 nm in a 1 cm colorimeter tube with a Spectronic 20 or equivalent.
7th-Prepared a standard curve using absorbance as the abscissa and standard concentrations as the ordinate. Extrapolate concentration of DMP in liquid smoke dilutions from this curve.
8th-Calculate mg DMP/ml liquid smoke using the following equation: ##EQU1##
To calculate mg DMP/g liquid smoke, divide result of above equation by the weight (g) of 1 ml. of liquid smoke.
For carbonyl determination, the reagents are:
1. Carbonyl-free methanol: To 500 ml. of methanol add 5 gm. of 2,4-dinitrophenylhydrazine and a few drops of concentrated HCl. Reflux three hours, then distill.
2. 2,4-Dinitrophenylhydrazine solution: Prepare saturated solution in carbonyl-free methanol using twice recrystallized product. Store in refrigerator and prepare fresh every two weeks.
3. KOH solution: Add 10 gm. of KOH solid to 20 ml. of distilled H 2 O and dilute to 100 ml. with carbonyl-free methanol.
4. 2-Butanone standard: Prepare solutions of 3.0 to 10 mg. of 2-butanone in 100 ml. carbonyl-free methanol for a standard curve.
The procedure is a modified Lappan-Clark method based on the procedure described in their article "Colorimetric Method for Determination of Traces of Carbonyl Compounds", Anal. Chem. 23, 541-542 (1959).
The procedure is as follows:
1st-To 25 ml. volumetric flasks containing 1 ml. of 2,4-dinitrophenylhydrazine reagent (prewarmed to insure saturation) add 1 ml. of diluted liquid smoke solution, or 1 ml. of standard butanone solution, or 1 ml. of methanol (for reagent blank).
2nd-Add 0.05 ml. of concentrated HCl to all 25 ml. flasks, mix contents of each, and place in water bath for 30 minutes at 50° C.
3rd-Cool to room temperature and add 5 ml. KOH solution to each.
4th-Dilute contents of each flask to 25 ml. with carbonyl-free methanol.
5th-Read at 480 nm against methanol blank set at absorbance of 0, (cuvettes-0.5×4 in (10.2 cm) or equivalent). Use Spectronic 20, or equivalent.
6th-Plot absorbance versus 2-Butanone (MEK) concentration in mg. per 100 ml. for standard curve.
7th-Prepare a standard curve using absorbance as the abscissa and standard concentrations (mg MEK/100 ml.) as the ordinate. Extrapolate concentration of MEK in liquid smoke dilutions from this curve.
8th-Calculate mg MEK/100 ml. liquid smoke by the following equation: ##EQU2##
To calculate mg MEK/g liquid smoke, divide the result of the above equation by the weight (in grams) of 100 ml. of smoke.
The procedures for determining the browning index are as follows.
Determination of Browning Index of Liquid Smoke
The browning index is a relative measure of the ability of carbonyls to react with the amino acid glycine. Tests have shown good correlation between the browning index values of a solution of smoke flavoring and the extent of brown color formation in meat surface. The test does not employ a standard curve as do some colorimetric analysies, but a standard is run to ensure accuracy. The reaction is carried out in dilute aqueous buffered solution. For each sample two test tubes are prepared, one with and one without glycine. The latter is necessary to account for the background color of the solution. The difference between the optical densities @ 400 nm is multiplied by the dilution factor to obtain the browning index in BIU/ml.
Reagents:
0.5M NaOH: Dilute 10 g to 500 ml in a volumetric flask.
0.1M potassium hydrogen phthalate buffer: to a two liter volumetric flask add 20.42 g potassium hydrogen phthalate and 152 ml 5.M NaOH. Dilute to volume. Check pH to ensure it is 5.5.
Glycine buffer: add 2 g glycine to a 200 ml volumetric flash and dilute to volume with phthalate buffer. Store below 10° C.
Glyoxal standard: add 0.5 ml of 40% glyoxal solution to a 50 ml volumetric flask. Dilute to volume with distilled water. React 1 ml of the standard solution according to the procedure below. The optical density should read 0.300. If not, adjust the concentration as necessary. Store below 10 C.
Procedure:
One pair of 20×150 mm test tubes is used for each sample.
Pipette 10 ml of the phthalate buffer into one tube and 10 ml of glycine phthalate buffer into the other. Cap the tubes with marbles and temper the tubes in a boiling water bath for 5 min.
Add 1 ml of the appropriately diluted solution to both tubes (the concentration in the dilution should be between 0.2 and 0.4 BIU/ml). Add 1 ml of distilled water to a tube containing 10 ml glycine buffer (reagent blank). Add 1 ml of glyoxal standard to a tube containing 10 ml glycine buffer (standard).
Allow the reaction to proceed at 100° C. for exactly 10 min., remove the tubes from the bath and place them in an ice bath for 2 min. Transfer the solutions to 1/2 inch cuvettes. Use the glycine-water solution blank to set the spectrophotometer to zero optical density @ 400 nm. Determine the optical density of both the reacted and unreacted samples and the standard.
Calculations: The optical density of the unreacted control is substrated from that of the reacted sample to obtain the net increase in the optical density due to the yellow-orange color formed by the browning reaction. If the O.D. of the glyoxal standard is other than 0.300, correct the reacted sample O.D. values by adding one half of the difference between the 0.300 and the value obtained to the O.D. difference obtained from the samples Multiply by the dilution factor to obtain the browning index units/ml.
Even though only the Rapid Thermal Processing apparatus was described herein, the invention defined by the following claims is intended to cover any use of the products of a fast pyrolysis method as liquid smoke flavoring.
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An aqueous wood smoke solution for flavoring foodstuffs is produced by heating in an oxygen starved atmosphere ground wood or cellulose to between 400° C. and 650° C. within 1.0 second; maintaining the said wood or cellulose and the primary pyrolysis vapors between 400° C. and 650° C. for between 0.03 and 2.0 seconds; reducing the temperature of the pyrolysis products to below 350° C. within 0.6 seconds; separating and collecting the water soluble liquid products; and diluting the said water soluble liquid products with water to achieve a partial phase separation and to reduce the benzo(a)pyrene concentration to less than 1.0 ppb.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority from Korean Patent Application Number 10-2009-0056414 filed on Jun. 24, 2009, the entire contents of which application is incorporated herein for all purposes by this reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an apparatus for recycling metal scraps, and more particularly, to an apparatus for recycling metal scraps that can convert the scraps, produced in the machining of a metal material, into a solid compact having a high specific gravity, so that the scraps are not lost due to oxidation when they are being melt, and convert the scraps without using cutting fluid, thereby reducing the creation of pollutants.
[0004] 2. Description of Related Art
[0005] The process of cutting a metal material produces various types of scraps, such as granular or spiral scraps. The scraps take a sizable amount, which is typically 5 to 10% of the weight of the metal material subjected to the cutting. Therefore, various methods are used to collect and recycle the scraps. For example, as for scraps produced in the cutting of a cast material, the scraps are melted again together with a molten source metal in a melting furnace, so that it can be reused as a raw material in the casting.
[0006] However, the collected scraps, which are input into the melting furnace, have a significantly small specific gravity relative to the molten source metal, so that the majority of scraps input into the melting furnace suspends on the surface of the molten metal without immersing into the molten metal while it is being melted. Thus, a great amount of the scraps is oxidized in the melting process by contact with air. Since the oxidized scraps lost their own properties of a source metal, they are screened and disposed. Thus, only 50% to 60% of the input scraps can be reused, thereby raising a problem such as a very low source recovery rate (recycling rate).
[0007] To solve this problem, a method had been proposed, in which the molten metal is rotated to make the input scraps immerse more easily in the molten metal, thereby reducing the loss of scraps due to oxidation. However, in order to use this method, special equipments for rotating the molten metal are required and a melting furnace should be separately fabricated to suit to the equipment, so that mounting costs for a melting apparatus increase greatly. Furthermore, the rotation of the molten metal results in a reduction in the lifetime of the melting furnace and an increase in the cost of energy that is consumed in the process.
[0008] Further, while there had been proposed a method that the suspended scraps on the surface of the molten metal are forcedly pushed and immersed in the molten metal, a problem also arises in that special equipments for immersing the scraps are required and an installation cost for a melting apparatus increases greatly, and for small, light scraps, it is difficult to immerse them in the molten metal, so that the effects of reducing losses of the scraps due to oxidation are degraded.
[0009] Meanwhile, the recovered scraps are impregnated with cutting fluid that is used for cutting a metal material. However, if the scraps impregnated with the cutting fluid are melted as they are, an environmental contamination arises due to combustion of the cutting fluid. To prevent this, according to the related art, a separate washing process for removing the cutting fluid was required. However, because of a large surface area of the scraps, a great amount of cost and time was taken in the washing process, resulting in a further deterioration in a recovery efficiency of the scraps.
[0010] The information disclosed in this Background of the Invention section is only for the enhancement of understanding of the background of the invention, and should not be taken as an acknowledgment or any form of suggestion that this information forms a prior art that would already be known to a person skilled in the art.
BRIEF SUMMARY OF THE INVENTION
[0011] Various aspects of the present invention provide an apparatus for recycling metal scraps which can compress the metal scraps to increase the specific gravity while removing cutting oil, thereby preventing oxidation of the scraps that occurs due to suspension on the surface of molten metal when they are being melted, and reducing the creation of pollutants due to combustion of the cutting oil.
[0012] In an aspect of the present invention, the apparatus for recycling metal scraps includes: a mold having an inner conversion cavity for converting the metal scraps, an inlet disposed in one longitudinal end thereof, and an outlet disposed in the other longitudinal ends thereof, the inlet and the outlet communicating with the cavity; a gate movably mounted near the outlet of the mold so as to open and close the outlet of the mold as the gate moves; a gate actuator moving the gate to an opening or closing position; a scrap feeder supplying the metal scraps into the cavity of the mold, a conversion plunger intruded into the cavity via the inlet of the mold and compacting the metal scraps to form a solid compact having a shape corresponding to the cavity; and a press actuator reciprocating the conversion plunger between inside and outside of the mold so as to provide a conversion pressure.
[0013] In an exemplary embodiment, the apparatus may further include a mold housing fixedly enclosing the mold, in which the mold is provided with a plurality of mold blocks, which is mounted in the mold housing adjacent to each other, thereby to define the cavity.
[0014] In an exemplary embodiment, the apparatus may further include a guide pad provided adjacent to the inlet of the mold and having a guide groove guiding the conversion plunger toward the cavity of the mold, and an inlet portion opened in an upper portion of the guide groove.
[0015] In an exemplary embodiment, the scrap feeder may include a hopper, which has an outlet facing the inlet portion of the guide pad, and a loader for transporting the scraps, received in the hopper, to the inlet portion of the guide pad.
[0016] In an exemplary embodiment, the loader may include a transporting screw provided in a vertical direction in the hopper, a driving mechanism rotating the transporting screw, and a transporting guide provided outside the transporting screw, in which the transporting guide has open scrap inlet and outlet in the upper and lower portion thereof, and a tubular passage between the scrap inlet and outlet.
[0017] In an exemplary embodiment, the apparatus may also include an auxiliary loader having a hydraulic cylinder and a push rod, in which the push rod is caused to vertically reciprocate in the hopper by the hydraulic cylinder, thereby transporting the metal scraps towards the outlet of the hopper.
[0018] In an exemplary embodiment, the gate may include an opening connected to and disconnected from the inlet of the mold as it moves.
[0019] In an exemplary embodiment, the apparatus may also include a guide housing mounted adjacent to a front end of the guide pad, and having therein a guide that movably supports the conversion plunger.
[0020] In an exemplary embodiment, the apparatus may also include an oil pan mounted on the lower side of the mold and collecting cutting oil discharged outside when the metal scraps are compressed.
[0021] According to exemplary embodiments of the present invention as set forth above, the following effects are provided.
[0022] (1) The metal scraps that were produced during processing a metal material are compressed to form a solid compact having a high specific gravity such that the metal scraps are immersed in the molten metal without suspending on the surface of molten metal when they are injected into the molten metal, and also to reduce cutting oil impregnated therein, thereby preventing occurrence of oxidation loss during melting of the metal scraps and thus increasing the recovery rate of the metal scraps and reducing the occurrence of pollutants due to combustion of cutting oil.
[0023] (2) The mold is provided with divided mold blocks, which reduce stress applied to the mold upon receiving a molding pressure, so that metal scraps can be compact-converted with a higher molding pressure into a compact having a higher specific gravity in a short time, thereby improving productivity, extending and reducing the lifetime and weight of mold, and providing smooth discharging of the cutting oil and therefore reducing the content of the cutting oil impregnated in the compact furthermore.
[0024] (3) The metal scraps received in the hopper are intruded by a certain amount into the mold without congestion by means of the transporting guide and transporting screw of the loader, thereby providing a smooth, precise feeding of the metal scraps and thus improving the productivity of the apparatus.
[0025] The methods and apparatuses of the present invention have other features and advantages which will be apparent from, or are set forth in more detail in the accompanying drawings, which are incorporated herein, and in the following Detailed Description of the Invention, which together serve to explain certain principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a front elevation view showing an apparatus for recycling metal scraps according to an exemplary embodiment of the invention;
[0027] FIG. 2 is a top plan view of the apparatus for recycling metal scraps shown in FIG. 1 ;
[0028] FIG. 3 is a side elevation view of the apparatus for recycling metal scraps shown in FIG. 1 ; and
[0029] FIG. 4 is an enlargement view of the converter of the apparatus for recycling metal scraps shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0030] Reference will now be made in detail to various embodiments of the present invention(s), examples of which are illustrated in the accompanying drawings and described below. While the invention(s) will be described in conjunction with exemplary embodiments, it will be understood that the present description is not intended to limit the invention(s) to those exemplary embodiments. On the contrary, the invention(s) is/are intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments that may be included within the spirit and scope of the invention as defined by the appended claims.
[0031] FIG. 1 is a front elevation view showing an apparatus for recycling metal scraps according to an exemplary embodiment of the invention, FIG. 2 is a top plan view of the apparatus for recycling metal scraps shown in FIG. 1 , FIG. 3 is a side elevation view of the apparatus for recycling metal scraps shown in FIG. 1 , and FIG. 4 is an enlargement view of the converter of the apparatus for recycling metal scraps shown in FIG. 1 .
[0032] As shown in the figures, the apparatus for recycling metal scraps includes a base 101 , a front plate 103 provided in front of the base 101 , a rear plate 104 provided in the rear of the base 101 , a plurality of tie bars 109 connected between the front and rear plates 103 and 104 , a converter 110 provided on the front plate 103 , a press 150 provided on the rear plate 104 , a scrap feeder 170 provided around the converter 110 , and a conveyor 190 configured to transport converted materials.
[0033] The base 101 is configured to provide a horizontal mounting plane, in which leveling bolts 102 are provided in certain intervals.
[0034] The front plate 103 and the rear plate 104 support the converter 110 and the press 150 , respectively, and are fastened with each other by the tie bars 109 , so that they can maintain the position when a conversion pressure is applied thereto. The front plate 103 has an outlet 105 that forms a discharge passage of compacts that are produced by compression in the converter 110 . The outlet 105 can be flared in the discharge direction in order to facilitate discharge of the converted materials.
[0035] The converter 110 receives the scraps supplied thereto, and produces converted materials in the form of single solid compacts from the scraps by compressing the scraps under the pressure applied from the press 150 . In the converter 110 , a gate 111 is connected to the inner side of the front plate 103 such that it can move up and down, and a gate actuator 113 is provided to drive the gate 111 up and down. Below the gate 111 , a bracket 114 is mounted on the front plate 103 , extending in the horizontal direction. A mold housing 115 is connected to the gate 111 and is fixedly provided on the upper portion of the bracket 114 , and a mold 116 is provided inside the mold housing 115 . A guide pad 117 is connected to the mold 116 and fixedly provided on the upper portion of the bracket 114 . A guide housing 118 is connected to the guide pad 117 and is fixedly provided on the upper portion of the bracket 114 .
[0036] The gate 111 blocks and communicates the inside of the mold 116 from and with the outlet 105 of the front plate 103 . In the blocking position, the gate 111 cooperates with the mold 116 to define a cavity 119 where metal scraps are converted. In the open position, the inside of the mold 116 communicates with the outlet 105 of the front plate 103 such that a compressed compact can be discharged from the mold 116 through the outlet 105 . For this, both the right and left sides of the gate 111 are coupled with the front plate 103 in such a fashion that the gate 111 can slide up and down. The gate 111 also has an opening 112 in the upper central portion thereof. The opening 112 of the gate 111 can have a guide section in one side thereof that faces the mold 116 , the guide section flared toward the mold 116 to facilitate the discharge of the compact.
[0037] The gate actuator 113 serves to move the gate 111 up and down so that the gate 111 allows the inside of the mold 112 to communicate with the outlet 105 in one position (e.g., a raised position) but blocks the inside of the mold 112 from the outlet 105 in the other position (e.g., a lowered position). The gate actuator 113 can be embodied as an actuator that performs a linearly-reciprocating motion, such as an electromotive actuator using a motor or an electromagnet. In this embodiment, the gate actuator is illustrated as a hydraulic cylinder that is coupled with a fixing member 120 on the upper portion of the front plate 103 and has a rod coupled with the upper portion of the gate 111 .
[0038] The bracket 114 provides a horizontal mounting plane where the mold guide 115 , the guide pad 117 and the guide housing 118 can be collinearly arranged. The bracket 114 has a passage 124 in one end thereof, which is coupled with the front plate 103 , such that the gate 111 can move up and down through the passage 124 .
[0039] The mold housing 115 encloses the mold 116 therein, and serves to maintain the shape of the mold 116 while resisting against pressure that is applied when the mold 16 is operating. The mold housing 115 defines therein a mold-receiving portion 125 , a seating portion 123 in one end of the mold-receiving portion 125 , and a plurality of bolt holes 126 formed radially in the seating portion 123 , the bolt holes 126 spaced apart from each other at predetermined intervals.
[0040] The mold 116 is configured to convert metal scraps, which are supplied into the mold 116 , into a solid compact. The mold 116 is in the form of a sleeve that has an open entrance in one longitudinal end thereof and an open exit in the other longitudinal end thereof, and also has an inclined portion 128 that expands in diameter to facilitate introduction of the scraps, which are subject to conversion.
[0041] Although the mold 116 can be formed as one body, it is preferred that the mold 116 be formed of a plurality of separate mold blocks 121 , as shown in the upper right part of FIG. 4 . Each of the mold blocks 121 is in the form of an arc, such that they can define therein a cavity 119 having a circular cross section when fitted inside the mold housing 115 . A flange 122 is provided on one end of each mold block 121 , which forms the entrance of the mold 116 . A plurality of the flanges 122 is intruded into the seating portion 123 of the mold housing 115 to support the conversion pressure. A plurality of coupling holes 127 , corresponding to the bolt holes 126 , are formed in the flanges 122 , such that the individual mold blocks 121 are coupled with the mold housing 115 via bolts.
[0042] The guide pad 117 is configured to receive scraps supplied from the scrap feeder 170 so that the received scraps are input into the mold 116 by a conversion plunger 151 of the press 150 . The guide pad 117 has a guide groove 129 , which guides the movement of the conversion plunger 151 in the same direction as the cavity 119 of the mold 116 does, and an open loading portion 130 above the guide groove 129 , so that the scraps can be supplied into the loading portion 130 . Preferably, the loading portion 130 can have a shape that expands upward.
[0043] The guide housing 118 is configured to guide the movement of the conversion plunger 151 while supporting the same. The guide housing 118 has a guide 131 mounted therein such that the conversion plunger 151 can be intruded into the guide 131 in the same direction as in the guide groove 129 of the guide pad 117 .
[0044] In addition, an oil pan 132 is provided below the converter 110 , and collects cutting fluid that is discharged when the scraps are being compressed.
[0045] The press 150 includes a press actuator 152 , which is fixed to the rear plate 104 and is arranged in the horizontal direction, a push rod 153 , which is reciprocally moved by the press actuator 152 to and from the converter 110 , and a conversion plunger 151 , which is coupled to one end of the push rod 153 to force the scraps input into the converter 110 .
[0046] In this embodiment, the press actuator 152 , which provides the scraps-converting pressure and force to the conversion plunger 151 , is illustrated and described as a hydraulic cylinder, which has an operating rod that can be extended and compressed. However, the press actuator can also be embodied as various types of actuators that perform a linearly-reciprocating motion using a motor or an electromagnet.
[0047] The push rod 153 is coupled to a movable portion of the press actuator 152 , for example, an outer portion of the operating rod, and is intruded into the converter 110 through the guide 131 of the guide housing 118 , so as to reciprocally move the conversion plunger 151 into and out of the cavity 119 of the mold 116 along the guide groove 129 of the guide pad 117 .
[0048] When the conversion plunger 151 is reciprocated by the push rod 153 , it forces the scraps, loaded in the upper portion of the guide pad 117 , into the cavity 119 of the mold 116 so that the scraps are converted into the form of a high-density block. Although the conversion plunger 151 can be provided integral with the push rod 153 , the conversion plunger 151 is provided as a separate member that is detachably coupled with the push rod 153 in order to facilitate replacement. This can reduce manufacturing costs and maintenance cost of the apparatus.
[0049] The scrap feeder 170 includes a support 171 erected from the base 101 , a hopper 172 provided above the converter 110 by the support 171 , an inclined loader 173 provided in one region inside the hopper 172 , and an auxiliary loader 174 erected in the other region inside the hopper 172 .
[0050] The hopper 172 is configured to have an expanding entrance in the upper portion and a narrowing exit in the lower portion. The exit is positioned above the loading portion 130 of the guide pad 117 . The hopper 172 can be designed with various shapes. However, in this embodiment, the hopper 172 is illustrated to have a slope 175 in one region and a vertical surface 176 in the other region in order to facilitate installation and operation of the loader 173 and the auxiliary loader 174 .
[0051] The loader 173 supplies the metal scraps from the hopper 172 to the guide pad 117 by forcing down the metal scraps through the exit. The loader 173 includes a rotatable transport screw 177 arranged on the slope 175 of the hopper 172 , a driving mechanism for rotating the transport screw 177 , and a transport guide 178 provided around the transport screw 177 .
[0052] The driving mechanism of the loader 173 includes a shaft holder 179 fixed on the upper portion of the hopper 172 , a rotary shaft 180 rotatably fitted into and coupled with the shaft holder 179 , with one end thereof coupled with the transport screw 177 , a follower sprocket 181 coupled with the outer end of the rotary shaft 180 , a drive sprocket (not shown) connected to the follower sprocket 181 via a chain, and a motor (not shown) for rotating the drive sprocket.
[0053] The transport guide 178 has an open scrap inlet 182 in the upper portion, a scrap outlet 183 in the lower portion, and a guide 184 having a circular tubular passage that extends from the inlet 182 to the outlet 183 .
[0054] The auxiliary loader 174 serves to force the metal scraps, congested inside the hopper 172 , toward the exit. The auxiliary loader 174 includes an air cylinder 186 erected in the upper portion of the hopper 172 by the support 185 so as to apply a downward force and a movable pusher 187 coupled with a rod of the air cylinder 186 to reciprocally move along the inner surface of the hopper 172 .
[0055] The compact conveyor 190 serves to convey a compact, which is discharged from the converter 110 after having been compressed. Although the scrap conveyor 190 can be formed as various types of conveyors, it is illustrated as a belt conveyor in this embodiment. The illustrated compact conveyor 190 includes a drive sprocket 193 provided on one longitudinal end of the frame 191 so as to be rotatable by a motor 196 , a follower sprocket 194 provided on the other longitudinal end of the frame 191 and connected with the drive sprocket 193 via a chain 192 , and a conveyor-belt 194 driven by the chain 192 . Holder plates 195 , which support the compact, are provided on the conveyor belt 194 at certain intervals.
[0056] Below, a description will be given of the operation of the apparatus for recycling metal scraps according to an exemplary embodiment of the invention.
[0057] Metal scraps, input into the hopper 172 of the scrap feeder 170 , are supplied into the converter 110 . If the scraps are simple particles, they can be naturally supplied by the weight thereof. The scraps are generally tangled with each other when collected, since they have complicated shapes. In general, it is impossible to naturally supply the scraps. Therefore, the loader 173 is operated to forcibly supply the scraps. That is, as the transport screw 177 is rotated, the scraps received in the hopper 172 are introduced into the transport guide 178 through the scrap inlet 182 , discharged through the outlet 183 , and then supplied into the loading portion 130 of the guide pad 117 . In addition, in some cases, the movable pusher 187 of the auxiliary loader 174 is moved up and down to supply a remaining amount of the scraps into the guide pad 117 .
[0058] When the scraps are supplied as above, the press actuator 152 drives the conversion plunger 151 into the converter 110 , thereby compressing and converting the scraps. That is, the conversion plunger 151 pushes the scraps into the mold 116 while proceeding on the guide pad 117 through the inside of the guide 131 , thereby converting the scraps into a tightly-compressed solid compact.
[0059] When the compression of the scraps is completed inside the mold 116 as above, the gate 111 is lowered and the exit of the mold 116 is moved to a position that communicates with the outside through the opening 112 and the outlet 105 , so that the compact is discharged to the conveyor 190 . Afterwards, the discharged compact is transported to a next process site by the conveyor 190 and is input into a molten metal for reuse as a casting material.
[0060] When the scrap compact is produced by the apparatus for recycling metal scraps according to an exemplary embodiment of the invention as above, it has a specific gravity equal to or more than that of the molten source metal. Thus, when the scrap compact is melted in the molten metal, it sinks inside the molten metal without floating on the surface of the molten metal. Therefore, it is possible to prevent the scraps from being lost due to oxidation, thereby significantly improving the recovery rate of the scraps.
[0061] Furthermore, the apparatus for recycling metal scraps according to an exemplary embodiment of the invention is configured such that the mold 116 is divided into a plurality of the mold blocks 121 . The stress applied to the mold 116 due to the conversion pressure is significantly reduced compared to that in the integral structure. This, as a result, makes it possible to convert scraps having a high specific gravity into a compact in a short time by applying a high conversion pressure to the scraps. In addition, it is possible to reduce the weight of the mold while increasing the lifetime thereof.
[0062] Moreover, cutting fluid, input together with the scraps, is discharged to the outside through the gaps between the individual mold blocks 121 of the mold 116 and is then collected by the oil pan 132 . Therefore, it is possible to raise the recovery rate of the cutting fluid and significantly reduce the content of the cutting fluid in the converted scrap compact, thereby significantly decreasing the amount of pollutants which would otherwise occur in a significant amount.
[0063] The foregoing descriptions of specific exemplary embodiments of the present invention have been presented for the purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teachings. The exemplary embodiments were chosen and described in order to explain certain principles of the invention and their practical application, to thereby enable others skilled in the art to make and utilize various exemplary embodiments of the present invention, as well as various alternatives and modifications thereof. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents.
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An apparatus for recycling metal scraps includes a mold having an inner conversion cavity for converting the metal scraps, an inlet disposed in one longitudinal end thereof, and an outlet disposed in the other longitudinal ends thereof, the inlet and the outlet communicating with the cavity; a gate movably mounted near the outlet of the mold so as to open and close the outlet of the mold as the gate moves; a gate actuator moving the gate to an opening or closing position; a scrap feeder supplying the metal scraps into the cavity of the mold, a conversion plunger intruded into the cavity via the inlet of the mold and compacting the metal scraps to form a solid compact having a shape corresponding to the cavity; and a press actuator reciprocating the conversion plunger between inside and outside of the mold so as to provide a conversion pressure.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional Patent Application U.S. 61/452,196 filed Mar. 14, 2011 entitled “Method and Apparatus for Increasing and Adjusting Distribution of Weight within a Golf Club Head”
FIELD OF THE INVENTION
[0002] This invention relates to golf clubs and more specifically to increasing the mass and adjusting the balance of said clubs.
BACKGROUND OF THE INVENTION
[0003] Golf is a popular game, not only in the United States, but also in many other parts of the world such as Korea, Japan, India, China, Germany, UK and South Africa. Within the last 5 years, the golf industry has seen steady growth of 5-15% annually in most regions of the world. According to a recent market study “Opportunities in the Global Golf Club Market 2004-2009” published by E-Composites, Inc., the golf club market in India and China will continue to see a growth rate of over 25% annually for the period 2010 - 2014 . The growing popularity of the game and the general affluence of golfers ensure a substantial market, which in 2010 was estimated as US $3.9 billion.
[0004] The market for manufacturers of golf clubs/golf shafts is crowded with small to large corporations such as Callaway, Taylormade, Acushnet, Ping Golf and Wilson. There are more than 100 manufacturers of golf clubs and golf club shafts around the world and about 50 of these golf club/golf club shaft manufacturers are in the USA alone. The remaining suppliers are mostly based in China, Taiwan, Korea, Japan, UK, and Germany.
[0005] Considering Callaway, one of the industry leaders, then in 2008 sales were divided between woods (24%), irons (27.6%), putters (9.1%), balls (20%), and other accessories (19.3%). With annual revenues of US$1,100 million in 2008 and US$950 million in 2009 woods, irons, and putters together accounted for approximately 60% of their revenue, US$1,230 million for the two years.
[0006] Over the years golf club manufacturers have released hundreds of new models featuring variations in the design of many elements of the golf clubs including hosel profile, heel, top line, toe, face, back, back cavity, sole, weighting for the head alone together with introducing steel variations, titanium and carbon fiber materials for the shafts, and weight, geometry, and polymeric materials for the grip that slides onto the upper portion of the shaft. Despite the massive research and development efforts, brand profiles built upon world renowned figures over the past decades such as Tiger Woods, Jack Nicklaus, Greg Norman, Seve Ballesteros, and Fred Couples the fundamental assembly of golf clubs has not changed for a century since the Thomas Horsburgh experimented with steel shafts in the late 1890s.
[0007] However, the designers of these hundreds of models, as well as the many tens of golf ball designs released over the years, do not have complete freedom in the design, shape, features, and materials of their products. Overall the design of golf clubs, golf balls and the resulting performance of these must meet the rules and regulations of the sport that are controlled by various national organizations, such as the United States Golf Association (USGA), in association with the The Royal and Ancient Golf Course at St Andrews, Scotland.
[0008] Consider a golf club manufacturer wishing to market their golf clubs in the United States then they should submit to the USGA a sample of a club to be manufactured for a ruling as to whether the club conforms with the Rules or not. Further, where a club, or part of a club, is required to meet a specification within the Rules, it must be designed and manufactured with the intention of meeting that specification.
[0009] With respect to clubs then the rules state it “must not be substantially different from the traditional and customary form and make”. The club must be composed of a shaft and a head and it may also have material added to the shaft to enable the player to obtain a firm hold. All parts of the club must be fixed so that the club is one unit, and it must have no external attachments. Considering golf club heads then these may incorporate mechanisms for weight adjustment and other forms of adjustability may also be permitted upon evaluation by the USGA. However, the club head must not be purposely changed by adjustment or by any other means during playing of a round of golf, and for any permissible method of adjustment it cannot be easily made by the golfer, all adjustable parts must be firmly fixed so that there is no reasonable likelihood of them working loose during a round, and all configurations of adjustment conform with the Rules.
[0010] When the golf club is in its normal address position the shaft must be so aligned with the club head so that:
(i) the projection of the straight part of the shaft on to the vertical plane through the toe and heel must diverge from the vertical by at least 10 degrees. If the overall design of the club is such that the player can effectively use the club in a vertical or close-to-vertical position, the shaft may be required to diverge from the vertical in this plane by as much as 25 degrees; (ii) the projection of the straight part of the shaft on to the vertical plane along the intended line of play must not diverge from the vertical by more than 20 degrees forward or 10 degrees backward.
[0013] Except for putters, all of the heel portion of the club head must lie within 0.625 inches (15.88 mm) of the plane containing the axis of the straight part of the shaft and the intended (horizontal) line of play.
[0014] The club head must be generally plain in shape and all its parts must be rigid, structural in nature and functional. The club head or its parts must not be designed to resemble any other object. It is not practicable to define plain in shape precisely and comprehensively. However, features which are deemed to be in breach of this general requirement for all and are therefore not permitted include, but are not limited to:
holes through the face or head (some exceptions may be made for putters and cavity back irons); features that are for the purpose of meeting dimensional specifications; features that extend into or ahead of the face or extend significantly above the top line of the head; furrows in or runners on the head that extend into the face; and optical or electronic devices.
[0020] For club heads on woods and irons these inadmissible features additionally include:
cavities in the outline of the heel and/or toe that can be viewed from above; severe or multiple cavities in the outline of the back that can be viewed from above; transparent material added to the head with the intention of rendering conforming a feature that is not otherwise permitted; and features that extend beyond the outline of the head when viewed from above.
[0025] Additionally, golf club heads must meet specific requirements in terms of dimensions, volume and moment of inertia. Considering woods then the dimensional requirements, which must be met when the golf club is in a 60 degree lie angle, are that:
the distance from heel to toe is greater than the distance from face to back; the distance from heel to toe is not greater than 5 inches (127 mm); and the distance from sole to crown is not greater than 2.8 inches (71.12 mm).
[0029] These dimensions are measured, as shown in FIG. 4 , on horizontal lines between vertical projections of the outermost points of the heel and the toe, and the face and the back, and on vertical lines between the horizontal projections of the outermost points of the sole and the crown. If the outermost point of the heel is not clearly defined, it is deemed to be 0.875 inches (22.23 mm) above the horizontal plane on which the club is lying.
[0030] The volume of the club head must not exceed 460 cubic centimeters (28.06 cubic inches), plus a tolerance of 10 cubic centimeters (0.61 cubic inches). When the club is in a 60-degree lie angle, the moment of inertia component around the vertical axis through the club head's center of gravity must not exceed 5900 g cm (32.259 oz in), plus a test tolerance of 100 g cm (0.547 oz in).
[0031] For irons, when the club head is in its normal address position, the dimensions of the head must be such that the distance from the heel to the toe is greater than the distance from the face to the back Likewise, there are dimensional rules for putters as shown in FIG. 5 that state that when the club head is in its normal address position, the dimensions of the head must be such that:
the distance from heel to toe is greater than the distance from face to back; the distance from heel to toe is less than or equal to 7 inches (177.8 mm); the distance from heel to toe of the face is at least two thirds of that from face to back; the distance from heel to toe of the face is at least half that from heel to toe of the head; and the distance from the sole to top of the head is less than or equal to 2.5 inches (63.5 mm).
[0037] For traditionally shaped heads, these dimensions will be measured on horizontal lines between vertical projections of the outermost points of the heel and the toe of the head, the heel and the toe of the face, the face and the back, and on vertical lines between the horizontal projections of the outermost points of the sole and the top of the head.
[0038] In respect of the striking face of the club head it must have only one striking face, except that a putter may have two such faces if their characteristics are the same, and they are opposite each other. In general the face of the club must be hard and rigid and must not impart significantly more or less spin to the ball than a standard steel face, although some exceptions may be made for putters. Except for such markings as listed below, the club face must be smooth and must not have any degree of concavity, and shall have a surface roughness within the area where impact is intended (the “impact area”) must not exceed that of decorative sandblasting, or of fine milling. The whole of the impact area must be of the same material (exceptions may be made for club heads made of wood). If a club head has grooves in the impact area they must meet the following specifications:
grooves must be straight and parallel, have a plain, symmetrical cross-section and have sides which do not converge, and have width, spacing and cross-section that is consistent throughout the impact area; the width (W) of each groove must not exceed 0.035 inches (0.9 mm); the distance between edges of adjacent grooves (S) must not be less than three times the width of the grooves, and not less than 0.075 inches (1.905 mm); the depth of each groove must not exceed 0.020 inches (0.508 mm); for clubs other than driving clubs, the cross-sectional area (A) of a groove divided by the groove pitch (W+S) must not exceed 0.0030 square inches per inch (0.0762 mm2/mm); and grooves must not have sharp edges or raised lips.
[0045] If a club head has punch marks then they must meet the following specifications:
the maximum dimension of any punch mark must not exceed 0.075 inches (1.905 mm); the distance between adjacent punch marks (or between punch marks and grooves) must not be less than 0.168 inches (4.27 mm), measured from center to center; the depth of any punch mark must not exceed 0.040 inches (1.02 mm); and punch marks must not have sharp edges or raised lips.
[0050] The center of the impact area of the club head, unless the club head is wood with an impact area made of a material of hardness less than metal, may be indicated by a design within the boundary of a square whose sides are 0.375 inches (9.53 mm) in length. Such a design must not unduly influence the movement of the ball on top of which decorative markings are permitted outside the impact area.
[0051] Accordingly, a designer seeking to design a golf club and/or golf club head that improves an aspect of play for a golfer, such as driving range, must comply with all the above features and others that have not been reproduced here. They must also consider the design of the golf ball itself as it is the combination of the two in conjunction with the golfer that determines ultimately the performance achieved.
[0052] Considering the golf ball then like the golf club it must not be substantially different from the traditional and customary form and make. The weight of the ball must not be greater than 1.620 ounces avoirdupois (45.93 gm), and the diameter of the ball must not be less than 1.680 inches (42.67 mm) at a temperature of 23±1° C. The golf ball must not be designed, manufactured or intentionally modified to have properties which differ from those of a spherically symmetrical ball. Further, the golf ball shall not have an initial velocity that exceeds the specified limit when measured on standard test apparatus approved by the USGA. Likewise the combined carry and roll of the golf ball, when tested on apparatus approved by the USGA, must not exceed the maximum distance specified when tested under conditions set forth in the Overall Distance Standard for golf balls.
[0053] If that was not enough, these rules are subjected to ongoing amendment and revision. As of 2011, these established that the initial velocity shall not be greater than 250 feet (75 m) per second, with a tolerance of +2%, and that the overall distance standard shall not cover an average distance in carry and roll exceeding 280 yards (84 m), with a tolerance of +6%.
[0054] Accordingly, the rules for both golf clubs and golf balls establish a design space within which designers operate in establishing every year the new designs that are marketed with promises of improved performance for the average golfer. These improvements may include, for example, the size of the sweet spot, the spin imparted to the golf ball, and the distance they can attain with their tee-shot. In recent years significant attention has been given to swing weight and counter-balance. The former is a measure of the total club head feel, and is used in order to achieve continuity amongst clubs for golfer and the latter is a measure of the location of the balance point of a golf club between the head and the grip.
[0055] Considering swing weight then low lofted irons start off lightest in weight, for example a 3-iron head may weigh 240 g, and because they have longer shafts give the feeling of high weight to the golfer due to the leverage effect of this longer shaft. The higher the iron number the heavier the club head, for example a pitching wedge may weigh 290 g, because their shorter shafts require a heavier club head in order to give the same relative feel for the golfer. Accordingly, golf club designers have provided golfers with means to adjust the weight of the golf club therefore over a small range in order to adjust the weight and thereby the feel to the golfer. Amongst these techniques are adding multiple weights into a chamber in the golf club head such as taught by Nygren in U.S. Pat. No. 4,076,254 entitled “Golf Club with Low Density and High Inertia Head”, depicted in FIG. 1 , and adding different weights into the sole of the club head as taught by Chen in U.S. Patent Application 2003/0,162,608 entitled “Structure of a Golf Club Head”, depicted in FIG. 2 . Likewise Duclos in U.S. Pat. No. 5,176,383 teaches to adding a weight within the body of a golf club head rather than at the back of the golf club, as depicted in FIG. 3 .
[0056] Beach et al in U.S. Patent Application 2002/0,160,854 entitled “High Inertia Golf Club Head”, depicted in FIG. 4 , teaches to adding weights into the base of the golf club head to adjust the inertia of the golf club head about an axis parallel to the ground. Beach also teaches that golfers prefer a driver golf club to have a total mass less than 250 grams, more preferably a total mass less than 230 grams and most preferably a mass less than 210 grams. Beach teaching that a lighter club head being preferred because it reduces the swing weight of the golf club but has less performance weight available to increase the moment of inertia of the club head.
[0057] Beach teaches that the structural members of the golf club head, i.e. the outer shell and the strike plate, typically have mass approximately 60%-90% of the total mass of the club head. The remaining 40%-10%, that constitutes the performance mass, is in the weight plugs of the invention taught by Beach. Typically within the prior art relating to weight golf club manufacturers have searched for ways to best distribute the performance weight so as to improve club head performance and have attempted to position most of the performance mass along the perimeter of the club head so as to increase the inertia of the club head.
[0058] Such perimeter weighting increases the inertia of the club head about the vertical axis and tends to make the club head more resistant to twisting during off-center hits but represents an inefficient use of the performance mass. Exceptions to the general trend of heel/toe weighting include Tseng in U.S. Pat. No. 6,620,053 entitled “Golf Club” teaches to inserting a weight into the shaft of the golf club rather than adjusting the weight of the club head itself, depicted in FIG. 5
[0059] However, if we consider a golf ball as a simple spherical object, without dimples and other aerodynamic effects such as drag and wind are neglected, then the trajectory calculation is really very simple. For any given time (t) the distance traveled (x component) is given by Equation (1):
[0000] x ( t )=( V o cos( m )) t (1)
[0000] and the height (y component) at any given time (t) is given by Equation (2):
[0000] y ( t )=( V o sin( m ))−( gt 2 /2) (2)
[0000] where V o is the initial velocity of the golf ball, g is gravitational acceleration 9.8 m/s/s, and m is the launch angle in radians.
[0060] However, this simplistic trajectory is impacted by other factors such as the Magnus effect that defines the lift generated by a spinning dimpled golf ball in flight. When a lofted club strikes the ball properly, the ball will tend to travel or roll up the clubface before it is launched. This causes the ball to anti-clockwise spin at a rate governed by the speed, loft and surface friction of the club head face at impact. Typical ball spin-rates are:
3,600 rpm—hit with a 10° driver (8° launch angle) at a velocity of 134 mph 7,200 rpm—hit with a 5 iron (23° launch angle) at a velocity of 105 mph 10,800 rpm—hit with a 9 iron (45° launch angle) at a velocity of 90 mph
[0064] The Magnus effect can be estimated by Equation (3):
[0000] F L ( dvr 4 a v 2 di 2 )(2 r ) (3)
[0000] where d is the density of air, v is the velocity of the golf ball, r is the golf ball radius, and a v is the angular velocity in radians per second. Additionally, we have to consider air drag and wind force, these being given by Equations (4) and 5 below:
[0000] F w =−C w V w (4)
[0000] F d =−C d V x −C d V x −C d V z (5)
[0000] where C d,w are the drag coefficients, V x,y,z are the components of the velocity in the x, y, and z directions, and V w is the wind velocity.
[0065] As such it is evident that the flight of the golf ball initially is determined by the velocity imparted in the strike from the golf club, coupled to with the lift angle and spin before loss of momentum and reduced spin rate from air resistance cause the golf ball to start dropping. As spin rate is additionally dependent upon loft angle of the golf club and its velocity at impact the initial velocity of the golf ball is critical to a golfer achieving distance with their strokes.
[0066] When the clubface of the golf club collides with the golf ball its total contact time is only approximately 0.0005 seconds but the peak force applied to the ball can be as high as 4000 pounds that actually compresses the golf ball at impact. The initial velocity of the golf ball after impact may be approximated by Equation (6) below:
[0000] V ball =( V club Coeff rest )/(1+( m ball /m club )) (6)
[0000] where V club is the velocity of golf club head at impact, Coeff rest is the coefficient of restitution that accounts for the momentum loss and the fraction of the energy into a collision that a “collision” returns, m ball is the mass of the ball, and m club is the mass of the club. Including the loft of the clubface results in Equation (7) wherein:
[0000] V ball loft =cos(loft) 2 sin(90−loft) V ball (7)
[0000] where loft is the loft angle of the club.
[0067] The coefficient of restitution for a typical golf ball is 1.67 and 45 g. Accordingly, for the golfer they have two ways to influence the initial velocity of the golf ball, and hence the distance for a specific club. The first is by increasing V club , the velocity of the golf club at impact, and secondly through using a heavier club, thereby increasing m club . However, generally for an individual swinging a heavier club leads to a reduction in the velocity of the club.
[0068] However, as the mass of the club head increases there is an increased tendency for the club head to twist the golf club in the golfer's hands such that the golf club face strikes the ball at an angle. Hitting the ball with what is known as an “open club-face” and a club-path from out to in will cause the ball to spin from left to right. The ball's flight will then curve to the right or “Slice.” Conversely, hitting the ball with a “closed club-face” and a club-path from in to out will cause the ball to spin from right to left. The ball's flight will then curve to the left or “Hook”.
[0069] Equation (6) is derived from the considerations of force, kinetic energy and momentum of the golf club. As the swing progresses, the golfer applies more and more force to the golf club head causing it to accelerate and so increase its speed. Accordingly, when a golfer swings for a long drive, the goal is to accelerate the club head so that it impacts the ball at just the right point, going in just the right direction, and moving as quickly as possible. To do so, the golfer exerts force with his or her arms on the shaft of the golf club, which in turn exerts force on the golf club head. This situation may be approximated as a double pendulum wherein the arms, pivoting at the shoulders, roughly behave as a first pendulum, and the hands, grip, and shaft, pivoting at the wrists, behave as a second pendulum attached at the end of the first. For a well-timed drive, at the moment of impact the upper pendulum, i.e. the arms, is swinging very rapidly about its pivot point, and, at the same moment, the club is swinging very rapidly around its pivot point.
[0070] During this rapid motion of the swing the golfer must also control the orientation of the golf club with the intention of hitting the golf club squarely, to avoid hook and slice, and vertical position to avoid what are known as thick shots, the club is hitting the lower portion of the ball primarily, and thin shots, primarily hitting the upper portion of the ball. Overall therefore golf is a very challenging game, mainly due to control of the club while swinging and at impact. Accordingly, if you can swing the golf club a shorter distance and/or at a slower speed you will have more control and a better result, one of the biggest challenges for recreational golfers is trying to increase club head speed and still maintain control, yet golf club manufacturers are telling golfers that higher club head speed is required for a better game. To achieve this requires the golfer to have increased flexibility, so the swing arc is longer, increased strength so they can accelerate the club head faster, which is almost impossible to achieve for “regular” players who represent the vast majority of golfers globally.
[0071] Accordingly, with a heavier club a golfer can utilize a shorter swing arc and/or a shorter shaft, giving further control, with a lower club head speed and achieve a significant length drive. This is something “regular” golfers will find relatively easy to do as opposed to fundamentally adjusting their physique, coordination etc.
[0072] Accordingly, it would be beneficial to increase the mass of the golf club without imparting a corresponding reduction in the swing velocity thereby allowing the golfer to achieve an increased distance in their game. It would be further beneficial for the additional mass to be added in a manner that reduces the tendency for the golfers swing to adjust resulting in increased hook or slice. As such the additional mass added to a driver may, according to embodiments of the invention, be compensated by the adjustment in the balance of the golf club and allowing for the additional mass to be added non-uniformly to the golf club head.
SUMMARY OF THE INVENTION
[0073] It is an object of the present invention to
[0074] In accordance with an embodiment of the invention there is provided a device comprising providing a golf club head, providing at least one predetermined region of a plurality of regions within the golf club head, and selectively adding to the at least one predetermined region a predetermined mass of a material.
[0075] In accordance with an embodiment of the invention there is provided a method comprising:
providing a golf club head having a predetermined weight, a first predetermined distribution of mass between a front strike face of the golf club head and a rear face of the golf club head, and a second predetermined distribution of mass between a first side of the golf club head positioned closer relative to a user when in use and a second side golf club head positioned away from the user when in use; providing a shaft for attachment to the hosel, the shaft being attached at a first distal end; providing at the second other distal end of the shaft a first predetermined weight at a first predetermined location; and providing at the second other distal end of the shaft a second predetermined weight at a second predetermined location.
[0080] In accordance with an embodiment of the invention there is provided a method comprising:
providing a first predetermined portion of a golf club head comprising at least one first recess of a plurality of first recesses; providing a second predetermined portion of a golf club head comprising a hosel and at least one second recess of a plurality of second recesses; providing a third predetermined portion of a golf club comprising at least a first face, the first face for mating to the first predetermined portion of the golf club head and having a third recess positioned to align with each first recess of the plurality of first recesses; providing at least a plug of a plurality of plugs, each plug comprising a first predetermined portion having a geometry compatible to fitting into a first recess in the first predetermined portion of a golf club head and a second predetermined portion having a geometry compatible to fitting into a second recess in the second predetermined portion of a golf club head, wherein each plug is comprised predominantly of at least a material having a density significantly higher than the materials that form each of the first and second predetermined portions of the golf club head.
[0086] 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
[0087] Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
[0088] FIG. 1 depicts a golf weighting technique according to the prior art of Nygren in U.S. Pat. No. 4,076,254;
[0089] FIG. 2 depicts a golf weighting technique according to the prior art of Chen in U.S. Patent Application 2003/0,162,608;
[0090] FIG. 3 depicts a golf weighting technique according to the prior art of Duclos in U.S. Pat. No. 5,176,383;
[0091] FIG. 4 depicts a golf weighting technique according to the prior art of Beach in U.S. Patent Application 2002/0,160,854;
[0092] FIG. 5 depicts a golf weighting technique according to the prior art of Tseng in U.S. Pat. No. 6,620,053;
[0093] FIG. 6A depicts a golf weighting technique according to an embodiment of the invention;
[0094] FIG. 6B depicts a golf weighting technique according to an embodiment of the invention;
[0095] FIG. 7 depicts a golf weighting technique according to an embodiment of the invention;
[0096] FIG. 8 depicts a golf weighting technique according to an embodiment of the invention;
[0097] FIG. 9 depicts a golf weighting technique according to an embodiment of the invention;
[0098] FIG. 10 depicts a golf weighting technique according to an embodiment of the invention;
[0099] FIG. 11 depicts a golf weighting technique according to an embodiment of the invention;
[0100] FIG. 12 depicts a technique for providing a controlled hard surface to a golf club body formed from a high density metal;
[0101] FIG. 13 depicts a technique for adjusting a golfer's feel for a golf club; and
[0102] FIG. 14 depicts a technique for adjusting a golfer's feel for a golf club.
DETAILED DESCRIPTION
[0103] The present invention is directed to golf clubs and more specifically to increasing the mass and adjusting the balance of said clubs.
[0104] Referring to FIG. 6A there is shown a golf putter 600 according to an embodiment of the invention. Once assembled the golf putter 600 would appear to be composed of heel 610 B, toe 610 A, and body 640 connected to the shaft 660 via hosel 655 . Disposed upon the visible exterior surfaces of body 640 are shaped recess 635 , top sight line 645 and rear sight lines 650 . Each of the heel 610 B and toe 610 A being attached to the body 640 via bolt 605 that screws into threaded recess 630 .
[0105] Disposed within the faces of each of heel 610 B and toe 610 are three first recesses 615 . Likewise with the faces of body 640 abutting the heel 610 B and toe 610 A are three second recesses 625 . Accordingly up to three slugs 620 can be inserted into the three second recesses 625 per face of the body 640 before the heel 610 B and toe 610 A are attached. It would therefore be evident that adding the slugs 620 to each side symmetrically increases the weight of the golf putter 600 whereas adding the slugs 620 in different combinations on either end of the golf putter 600 allows the weight to be increased but also distributed asymmetrically between heel 610 B and toe 610 A.
[0106] Considering a golf putter 600 A formed from stainless steel then the density of the body 640 , heel 610 B and toe 610 A would be approximately 8 g/cc, c.f. iron at 7.87 g/cc. For example 304 stainless steel has a density of 8.03 g/cc. Examples of materials for increasing the mass of these elements individually, in combination, or in combination with the slugs 620 are listed below in Table 1.
[0000]
TABLE 1
Density of Potential Weighting Materials for Golf Clubs
Relative to 304
Material
Density g/cc
Stainless Steel
Tin
7.300
0.91
Copper
8.940
1.11
Silver
10.490
1.31
Lead
11.340
1.41
Mercury
13.593
1.69
Tungsten carbide
15.800
1.97
Tungsten
19.300
2.40
Platinum
21.400
2.67
[0107] Optionally, each of heel 610 B and 610 A may be formed from a material of increased density along with the slugs 620 or they may be formed from different materials to each other and/or the slugs 620 . Accordingly if each of the first and second recesses 615 and 625 are filled with a slug of tungsten, rather than air, the increased mass of the golf putter 600 is 3.55 g per slug 620 . If all 6 slugs as shown are employed then the increased mass is 21.g. Making the slugs 620 2 cm long the increase in mass of the golf club is 42.6 g. Increasing the diameter of the slugs 620 to 1 cm results in an increase in mass of the golf putter 600 by up to 170 g. As such in terms of asymmetry the heel 610 B in this instance may be imbalanced by up to 85 g against a golf putter 600 g without slugs 620 bringing the center of gravity of the golf putter 600 closer to the shaft 660 . Alternatively the toe 610 A may be imbalanced by up to 85 g against a golf putter 600 g without slugs 620 moving the center of gravity of the golf putter 600 further away from the shaft 660 .
[0108] Whilst the approach shown in FIG. 6A was for a golf putter 600 the approach may be applied equally to a golf driver. However, as the golf driver is larger more slugs 620 may be inserted. Such a structure being shown by insert 690 in FIG. 6A wherein a driver is configured with 11 slug inserts for each interface between heel and toe and central body. It would be apparent to one skilled in the art that the pattern may for example be a row of 4 along the bottom of the club and a further 3 to the upper rear thereby removing any recesses closer to the face of the club.
[0109] Now referring to FIG. 6B there is depicted an alternate embodiment of the invention for weighting a golf club comprising a body 6150 and shell 6100 . Referring initially to first view 6000 A an elevation of the body 6150 is shown on the back surface 6300 away from the strike face 6250 . Disposed within the back surface 6300 of the body 6150 are a plurality of threaded holes 6050 that are disposed to the heel, closer to the hosel 6350 , centre, and toe, farther from the hosel 6350 . The centre threaded holes 6050 being set into a pattern going from below an axis of the centre of gravity of the unweighted golf club to above the axis.
[0110] Referring to second view 6000 B the body 6150 is shown in plan elevation with plug 6200 inserted into the threaded holes 6050 . Accordingly it would be evident to one skilled in the art that the weighting of the golf club can be increased by adding plugs 6200 to the body 6150 and that the distribution of the weight may be adjusted either to the heel/toe of the golf club or above/below the centre of gravity of the unweighted golf club therein adjusting the location of this centre of gravity to for the user. Referring to third view 6000 C the body 6150 is shown assembled with sell 6100 so that the golf club has an improved aerodynamic profile, aesthetic appearance, and compliance to golf rules. It would also be evident that by making the threaded holes 6050 with a small thread, such as M3 or 6-40 UNC for example, that the pitch of the threaded holes 6050 may be set small allowing multiple locations to be provided in the back surface 6300 even if all are not populated with larger plugs 6200 . Alternatively the outer diameter of the plug may be close to the diameter of the threaded inserts allowing a higher density of plugs 6200 to be added to the golf club. Alternatively plugs of various dimensions and/or materials may be provided to provide adjustments in the incremental weight added to the club through each plug added.
[0111] Referring to FIG. 7 there is depicted an alternate embodiment of the invention for weighting a metal golf club 700 wherein the weighting is applied to a hollow shell body 710 that has disposed within a chamber 720 . Access to the chamber being obtained through an orifice 730 that is sealed with plug 740 . Considering materials for golf club heads such as aluminum (melting point 660° C.), 304 stainless steel (1400° C.), and 316 stainless steel (melting point 1450° C.) then it would be evident to one skilled in the art that there is significant flexibility in selection of solder. Referring to Tables 2 and 3 the properties of common materials within solders and the resultant solders are summarized.
[0000]
TABLE 2
Properties of Materials in Common Solders
Material
Melting Point (° C.)
Density (g/cm-3)
Silver (Ag)
1765
10.49
Zinc (Zn)
419.5
7.14
Tin (Sn)
231.9
5.79 (grey)
Lead (Pb)
327.5
11.34
Bismuth (Bi)
271.5
9.78
Antimony (Sb)
630.6
6.70
Indium
156.6
7.31
[0000]
TABLE 3
Properties of Some Common Solders
Material
Melting Point (° C.)
Density (g/cm-3)
Pb98Sn2
316
11.5
Pb75Sn25
183
9.95
Sn50Pb50
183
8.56
Bi52Pb32Sn14
96
9.64
In50Sn50
118
6.54
Sn50Zn50
199
6.19
[0112] Some solders, such as In50Sn50 have good wetting to ceramics allowing their use in conjunction with ceramic golf club bodies, such as putters and irons. Sn50Zn50 has good wetting to aluminum. As such the body of the golf club 710 may be heated or unheated and molten solder added into the chamber 720 to add weight to the club.
[0113] Referring to FIG. 8 an alternate embodiment is depicted in side elevation 800 and plan view 850 respectively. As shown in side elevation 800 a golf club head 810 has three access points 820 , 830 and 840 on the rear face. Referring to plan view 850 it can be seen that first access point 820 is coupled to first chamber 870 , second access point 830 is coupled to second chamber 860 , and third access point 840 is coupled to third chamber 850 . Accordingly, not only can the weight of the golf club be increased significantly but the distribution of that weight can be adjusted between the centre and towards the heel/toe.
[0114] Now referring to FIG. 9 there is depicted wherein a golf club 910 has been patterned with multiple recesses 920 through 995 respectively that may be filled with low melting point alloy, i.e. a solder. Accordingly the multiple recesses 920 through 955 allow for a more complex adjustment in the distribution of weight and the total weight added. Optionally, a single base cover may be attached over the bottom of the club once the multiple recesses have been accessed for the addition of the low melting point alloy. Such a cover providing a cosmetic finish but also providing a smooth lower surface for improved aerodynamics.
[0115] Referring to FIG. 10 an alternate embodiment is presented wherein the main body of the golf club head 1070 has a recess, not shown for clarity formed within it. In the bottom of the recess are three threaded inserts, not shown for clarity, that accept first to third screws 1010 , 1040 and 1060 respectively. Fitting into the recess are first insert 1020 , second insert 1030 , and third insert 1050 . Accordingly if first to third inserts 1020 , 1030 , and 1050 are formed from a fibre reinforced polymer (FRP) then they will have a density of approximately 1.6-2.0 gcm −3 thereby offering a golf club head 1070 weight essentially determined by the body of the golf club head. However, if first to third inserts 1020 , 1030 , and 1050 are formed from tungsten then these will have a density of 19.3 gcm −3 thereby increasing the weight of the golf club head 1070 . It would also be apparent to one skilled in the art that one, two or all three inserts may be changed from FRP to tungsten providing differing weights overall and differing weight distributions. Likewise third insert 1050 may be replaced with one from copper, density 8.94 gcm −3 , whilst first and second inserts 1020 and 1030 are replaced with tungsten. In this manner the weight is increased but a distribution towards the heel is achieved. Alternatively each insert may be replaced by two inserts such that a thinner FRP insert and a thinner metallic insert are combined to provide weights that are increased but not as heavy as complete replacement of the insert(s).
[0116] Referring to FIG. 11 there is shown another embodiment of a golf club head 1100 according to an embodiment of the invention. Within the preceding embodiments weight has been added to a lower weight club head. In FIG. 11 this is reversed wherein the golf club head 1100 is initially formed at the maximum mass, for example through the use of a thick tungsten sole plate. Subsequently, material is then selectively removed through post-processing, for example, milling such that material is removed from predetermined areas 1110 to 1130 respectively. Such post-processing reduces the weight and also allows the weight distribution to be modified front to back or heel to toe. It would be apparent that complex or simple patterns of material removal might be considered without departing from the scope of the invention.
[0117] Referring to FIG. 12 an alternate structure for a golf club head 1200 is depicted comprising a base element 1210 , body element 1220 and core 1230 . Body element 1220 for example may be formed from a glass/carbon/basalt fiber FRP or a ceramic such as alumina, having a typical density of 4 gcm −3 , or tungsten carbide, density 15.8 gcm −3 . Core 1230 may be formed from a material such as tungsten that is then selectively post-processed, such as by machining to remove material. The core 1230 being bonded to the body element 1220 . Formed upon the face of golf club head 1200 is an impact area 1240 , formed for example by the selective deposition of tungsten, diamond or other material to form the impact surface.
[0118] Alternatively, core 1230 may be formed from materials with varying densities such as FRP, aluminum, and tungsten to provide a series of increasing weights for the overall golf club head 1220 . The body element 1220 may also be formed from a progressive sequence of materials. In the case that the body element 1220 for example is formed from tungsten then the impact area 1240 may be formed from tungsten carbide through the carbonization of tungsten.
[0119] As discussed supra the “feel” of a golf club to a golfer can be adjusted through the position of the balance point. In the embodiments presented supra the focus has been to increased golf club weight. Considering golf club 1300 then this is achieved together with an adjustment in “feel” or swing weight through the provisioning of a counter-balancing weight in the grip portion 1300 B of the club. Accordingly, there is shown in the hosel-shaft region 1300 A a first in-shaft weight structure and in the grip portion 1300 B a second in-shaft weight structure. For simplicity these are depicted as being the same. Accordingly a hollow shaft 1310 has a tapered inner channel, not identified for clarity, receiving a bar-like weight 1320 . The weight 1320 , being shaped to mate with the inner channel. The hollow shaft 1310 further has a threaded inner periphery 1315 defined at its thin end 1313 , and the threaded intermediate section 1333 of the structure 1330 is engaged with the threaded inner periphery 1315 in such a way that its annular stop 1331 abuts the thin end 1313 of the shaft 1310 and its boss 1335 fits in the recess 1321 of the weight 1320 . As a result, the structure 1330 is connected to the shaft 1310 .
[0120] A secondary weight 1360 may be additionally received in the channel of the hollow shaft 1310 , if necessary. The secondary weight 1360 being located adjacent to an end of the weight 1320 opposed to the structure 1330 , and has a boss 1361 configured to fit in the recess 1322 of the weight 1320 . The secondary weight 1360 may further have a recess 1362 for the addition of a third weight. The hosel 1330 and the weight 1320 or weights 1320 , 1360 may be joined to the shaft 1310 through a resin 1370 , which may also be applied to the recesses 1321 , 1322 and the bosses 1335 , 1361 . In this case, the hollow shaft 1310 has a vent 1314 defined therein, in order to let air into the hollow shaft 1310 to help consolidation of the resin 1370 , as well as to lead surplus resin 1370 out of the hollow shaft 1310 .
[0121] Accordingly through the combination of the weight 1320 or weights 1320 , 1360 the overall weight of the golf club 1300 can be adjusted but also the “feel” adjusted by adding more counter-balancing weight to the grip of the golf club 1300 .
[0122] Referring to FIG. 14 there is shown an alternate golf club 1400 providing increased weight, counter-balancing but with increased adjustment. Accordingly in each of the hosel attachment region 1400 A and grip region 1400 B of the golf club 1400 an adjustable weight structure is provided. As shown the shaft 1450 has disposed a first plate 1420 and a second plate 1460 . Running between first plate 1410 and second plate 1460 is lead screw 1430 that has a key recess 1410 at the end with first plate 1420 . Lead screw 1430 being free to rotate relative to first and second plates 1420 and 1460 respectively. Attached to the lead screw 1430 is weight 1440 such that rotation of the lead screw 1430 through the use of the key in key recess 1410 moves the weight vertically along the length of the lead screw 1430 . Accordingly, the weight(s) can be adjusted vertically with respect to the golf club 1400 . Optionally with a long lead screw multiple weights 1440 may be added to one or both structures. As such the golf club weight can be increased; the “feel” adjusted through counter-balancing and the golf club 1400 set to each individual gofer's preferred set-up.
[0123] It would be evident that the embodiments of the invention above may be employed discretely or in combination. For example weighting the golf club head with an asymmetric weighting and counter-balancing through a weight in the grip of the golf club.
[0124] 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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Every amateur golfer wishes to improve their game. Doing so is usually achieved through significant practice and the hit-and-miss search for the right golf club. Accordingly to embodiments of the invention golf clubs imparting increased driving range through an overall increase in the mass of the golf club are presented. Additional aspects of the invention relate to achieving this without imparting a corresponding reduction in the swing velocity as well as providing for the addition of the mass a manner that reduces the tendency for the golfers swing to change, and allows for adjustment to address their natural tendency to hook or slice. As such the additional mass added to a driver may, according to embodiments of the invention, be compensated by the adjustment in the balance of the golf club and allowing for the additional mass to be added non-uniformly to the golf club head.
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DESCRIPTION OF THE PRIOR ART
The use of vacuum pressure in municipal and domestic waste disposal systems is not of recent origin. The 1895 edition of Chambers Encyclopedia describes a pneumatic system where aerial suction was used in place of water. Of a more recent date, are the vacuum toilet systems built in Sweden by Liljenthal. The Liljenthal type toilet has a number of little pockets in the drain lines, so that the waste matter is moved only a short distance at a time every time that it is flushed. The waste matter may move a third of the distance to the waste holding tank and then stop and form another pocket; and then the next time it is flushed, it might move all the way into the tank. In this manner, the waste matter can be flushed up-hill over great distances; much more distance than the differential pressure in the system would indicate; because it moves so far and then it sits in a pocket, and then the next time it moves a little again. In a sense, the waste matter moves a step at a time.
However, with respect to airplanes, the recovery of sufficient liquid from the waste matter and recycling this as the flush water for cleaning the toilet bowl, in combination with a vacuum-powered transmitting system, has, to the inventors' knowledge, not been used. In the present invention, the filtration process and the entire method of recirculation, i.e., wherein the liquid from the waste matter is removed and then used as the flushing liquid, in combination with a vacuum-powered system, has been specifically developed for the high altitude passenger carrying airplane. Also specifically developed for the airplane, is the static filter unit in the waste holding tank.
SUMMARY OF THE INVENTION
The invention relates to a vacuum-flush toilet waste system for passenger carrying aircraft such as the Boeing 747, the Lockheed L1011, the McDonnell Douglas DC-10, and the other large passenger capacity aircraft; and, more particularly, to a vacuum-powered transmitting system in combination with a filtration process that recovers sufficient liquid from the waste matter so that the liquid can be recycled as the flushing fluid for cleaning the toilet bowl.
Sanitary installations on commercial aircraft have long represented an area where improvements have been sought, both by the aircraft manufacturers and the airline operators of commercial aircraft. Some of the reasons for this are the high degree of attention that the existing systems require and their relatively low level of reliability. From the airlines of users' point of view, the following points are of importance: the weight and cost should be low; the airplane interface should be simple, so as to permit a flexible floor plan; the facility should be as easy to move into and out of the airplane as a cargo container; and it should be self-contained and positively sealed to prevent leakage to aircraft structure with the resulting corrosion problems. Also, for all practical purposes, the toilet unit in the lavatory should be noticeably and functionally as close to home toilet use as possible in order that the user not be confused.
The vacuum-flush system of the present invention meets these objectives through the use of a recirculating system; and functions in a manner somewhat similar to commercial type toilets to the extent that fluid is used to wash down the waste matter in response to the operation of a flush valve.
The vacuum-flush system of the invention will handle any kind of waste and paper products that can be handled in the presently known commercial type toilets. But, like a home flushing toilet, it is not designed to be a "catch-all" for other types of refuse like: bottles, discarded clothing, bulky diapers, spray cans, etc.
The pneumatic vacuum-powered toilet flush system of the present invention utilizes a central waste collection tank at a remote location relative to the toilet units in order to provide a more sanitary and odor-free lavatory and the differential pressure at altitude for operation of the system. The advantage of the single, centrally and remotely located, waste collection tank is that no single toilet can be overfilled by excessive use; as is sometimes the case with existing self-contained capacity toilets. With a single tank of approximately 200 gallon capacity, for an aircraft like the Boeing 747, it would give a net usable capacity of at least 150 gallons and result in a favorable increase in net capacity; since, the present system has a total usable capacity of only approximately 120 gallons. Another advantage of the vacuum system of the present invention is that should a larger capacity or "over-size"tank be desired at a later date, to meet a change in passenger accommodations or for a special purpose such as the desire for less frequent servicing, it can easily be accomplished with a weight versus capacity, incremental change, of approximately 1 pound for each 3 gallons of increase in capacity.
Because the drain lines of the present invention do not have to be positioned below the toilet bowl, or sloping downward toward the waste storage tank as with conventional home gravity drain systems, the waste storage tank can be positioned at any location with respect to the toilet bowl and still function properly. In fact, the drain lines could go uphill. However, from a safety and sanitary standpoint, it is desirable that the waste storage tank be remotely located and below the toilet bowl; because, there is an added element of safety should there be a leakage or breakdown in the system. It would not be desirable to have a backup of the waste material or leakage into the toilet compartment.
Another object of the invention is to permit the use of smaller diameter drain lines than the presently known four inch diameter drain lines which have to be installed with a continuous slope for draining the waste by the force of gravity. Employing a gravity drain method imposes severe structural restrictions on the location of both the lavatories and the drain lines within the interior of the aircraft; whereas, with the vacuum-powered transmitting system of the present invention, drain lines as small as 11/2 inch to 2 inches in diameter, can be used. This simplifies the installation in an airplane and in addition, reduces the weight penalty. The vacuum-powered system provides flexibility in locating the toilet units within the interior of the airplane because there is no slope required in the drain lines. Also, one can eliminate the conventional waste water drain system, including drain masts, by connecting it to the vacuum system, if holding tank capacity permits. However, in order to make certain that all waste, like small bottles, etc., which enter into the tubing will pass through the drain lines, a 2 inch diameter tubing size is used for the main or trunk lines and then the diameter size is reduced to 13/4 inch for the branch lines which enter into the main drain lines; and with a further reduction in diameter size a 11/2 inch for the opening at the bottom of the toilet bowl. This selection of graduated line sizes reduces the chance for clogging once the object has entered into the drain line tubing. However, in order to prevent long objects, that may be deposited into the toilet bowl, from clogging the drain lines at an inaccessible location, a sharp bend or trap is located right at the inlet to the main tubing run so that anything that passes this trap could complete the journey. Therefore, except for the object arresting bend or trap, the recommended bend or bend radii in the drain line tubing should be four times the diameter of the tube. Further, in order to prevent the buildup of waste material in the drain lines, the interior surface of the tubing, which is in contact with the waste material and also the interior of the toilet bowl, should be smooth and of a non-sticky material.
Another object of the invention is to provide positive venting or a vacuum breaker in the upper periphery of the toilet bowl that is designed to make it impossible for the user to pressure seal the toilet bowl even though the toilet seat is in the raised position and he has seated himself directly onto the toilet bowl. This positive venting of the toilet bowl is to prevent any possibility of injury to the user by the pneumatic vacuum force created by the flushing action, in the event that a person is seated on the toilet bowl without the use of the toilet seat which would normally provide such venting due to its spaced relationship with the upper surface of the bowl. There have been instances where an overly stout person has raised the toilet seat for the purpose of increasing the seating opening size, and seated himself directly onto the toilet bowl in sealing engagement therewith. Even with gravity flow waste flush system, the pressure differential is great enough to injure the person; but with the pneumatic vacuum flush system of the present invention, there is a much higher pressure differential force created and it is most imperative that the toilet bowl be positively vented.
One of the advantages of the vacuum pressure toilet system of the present invention, from an airline point of view, is that the ground servicing operation is simplified by having a single service location. In addition, no flushing or rinsing cycle is required. Only the remote holding tank is recharged with flushing fluid and this eliminates the danger of overfilling the toilets with priming liquid which has, in some instances, resulted in flooding of the airplane interior.
Another advantage of the vacuum toilet system is that it decreases the weight penalty of conventional gravity drain systems and in addition, provides cost savings by decreased maintenance expenses. An analysis comparison between the existing system on the Boeing 747 and the vacuum toilet system shows an estimated 30% weight savings over the present system and with fewer parts and less complexity than the existing system.
Another advantage is that due to the smaller diameter of the plumbing lines and the absence of control cables for each individual waste tank valve, the installation of the vacuum powered system is much simpler and will result in substantially less installed cost. Also, with respect to non-recurring costs associated with the vacuum powered system, if the development cost is amortized over 100 airplanes, the total cost per airplane system is less than that of the existing systems.
Another advantage is that it is possible to retrofit this system in existing airplanes with a minimum of technical effort and realize a substantial decrease in system weight and lower maintenance costs.
Another advantage is the possibility of using the system for the disposal of galley wastes, provided that grinders or some other means are used for breaking up the waste matter thrown into it.
Another advantage is that vacuum cleaner type outlets could be located throughout the interior of the airplane so that the vacuum power of the system could be used to clean the interior of the airplane or vacuum the rugs in a manner similar to a central vacuum cleaning system.
Further, it is contemplated that the waste matter at the collection tank could be neutralized, condensed and compacted into approximately five percent of its original volume. In this way, removal of the waste could take the form of just carrying out a sealed plastic bag and no raw sewage would ever have to be handled. Also, the removal time periods of the compacted waste residue could take place at intervals of weeks instead of daily as is presently done.
These, as well as other objects and advantages of the invention, will be more clearly understood from the following description when read with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the preferred embodiment of the invention and depicts the layout of the vacuum powered waste disposal system as it can be installed in a Boeing 747 type airplane;
FIG. 2 is a perspective view similar to FIG. 1, but is enlarged to show the assemblies and components in more detail of the forward and mid-section of the fuselage;
FIG. 3 shows in schematic form the preferred embodiment of the vacuum powered waste disposal system;
FIG. 4 is a graphic plot of waste velocity vs. the value of the initial vacuum in the waste holding tank;
FIG. 5 is a graphic plot of the vacuum decay in the waste holding tank vs. the initial vacuum for a typical flush cycle;
FIG. 6 is a graphic plot of the velocity of a waste load vs. the distance from the flush valve;
FIG. 7 is a graphic plot of the velocity of a quantity of waste vs. the volume of waste;
FIG. 8 is a graphic plot of the amount of air space required vs. the suction pressure that could be applied to a person if there were insufficient venting of the toilet bowl;
FIG. 9 depicts a toilet seat lid with the location, in circles, of five pickup probes that were utilized for negative pressure tests.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a perspective view of the preferred embodiment of the invention and depicts the layout of the vacuum powered waste system as it can be installed in a Boeing 747 type airplane or as it might be installed in other large passenger carrying aircraft like the McDonnell Douglas DC-10 and the Lockheed L1011; and FIG. 2 is an enlargement of the forward and mid-section of the fuselage shown in FIG. 1. With respect to FIGS. 1 and 2, 14 main deck lavatory locations 20 to 33 and three above the deck lavatory locations 34 to 36 are shown; and in addition, the galley 37 and vacuum tank storage area 38 are also indicated.
The system is a recirculating flush liquid type, that utilizes a nominal vacuum pressure of 6 to 8 PSIG, to move the waste matter from all of the toilets, wash basins, galleys and floor drains, to a single waste holding tank 40. For an aircraft the size of the Boeing 747, it would only be necessary to position one 200 gallon waste holding tank amidships; and as shown, the waste tank 40 is located in an unpressurized area 38 in the mid-section of the fuselage, which is below and outside of the pressurized shell of the passenger compartment, and inside of the body fairing of the fuselage; preferably in a dry area. As shown, this is a good location relative to the airplane's center of gravity; and is also central to the lavatory complexes. With the waste holding tank 40 being positioned below the passenger compartment, it permits a portion of the lavatory complex to operate as a gravity drain system, in the event of a vacuum failure; and with the waste tank 40 outside of the pressure shell, any back flow of odors through the drain valves is prevented since the normal flow path for tank leakage, overflow, and odors, will be out of the airplane rather than into it.
The system, as shown, has three main drain lines 41 to 43 coming into the waste tank 40; and three main flush fluid lines 44 to 46. Each of the main drain lines and main flush lines comes from a cluster of toilets. Therefore, in the event of a blockage, only one of the clusters of toilets would become inoperative, i.e., those that were connected to that particular main line. No matter how a system is designed and built, sometimes things go wrong, such as a clog-up or a rupture in the line, and it is certainly desirable that these events and their consequences be limited. Since a rupture is more rare than the possibility of a clog-up, the system is designed such that a basic or initial restriction is located right in or at the base of the toilet fixture such that if a solid object is small enough to go through the initial restriction then it should go all the way into the waste tank 40. There is a little step-up in pipe size, i.e., the diameter of the drain lines increases slightly as the waste material feeds through the system, in order to make certain that a jam isn't caused as would occur if there were a step-down arrangement.
The minimum diameter of the vacuum drain lines 41 to 43 could be smaller than 2 inches; but, on a public use system like an airplane, where there is very little control over the public's abuse of it, and it would not be desirable to go any smaller than the nominal 2 inch diameter. In the home or on a private boat, the vacuum drain system could be operative with as little as 3/4 inch pipe size. If certain precautions were taken, e.g., the present type of big lofty paper seat cover could not be used; a special type of paper seat cover would have to be used; and it would have to be made certain that feminine sanitary napkins were not deposited.
The nominal 2 inch diameter drain size will handle all of the common paper covers and waste that is normally deposited in a commercial or public toilet system. Some of the things that may find their way into toilets are cosmetic bottles or alcoholic beverage bottles used on airplanes. Rather than throwing them into the trash can, they are thrown into the toilet. One of the reasons for this may be that the present day toilets on airplanes have a large opening at the bottom of the toilet bowl which appears as if it will handle the size of the discarded object. However, even the 2 inch diameter size will not serve as a waste basket. Therefore, the bottom of the toilet bowl is designed such as to give the visual impression that the opening size will only pass normal toilet waste matter which will discourage anyone from trying to get rid of large objects by dropping them into the toilet. The actual size of the opening is designed to be hidden, such that it appears rather small but when the flush valve is operated the opening is made larger. Also, a restriction is made at the base of the toilet bowl so that objects too large to pass through the 2 inch diameter size drain line will be stopped and can be fished out instead of going into the line and cause a blockage at some junction. Further, the restriction has a bend in it so that long thin objects like a pencil are likewise stopped and fished out before they cause a blockage in the line. The drain system is designed such that whatever does go through the restriction, will be conducted all the way into the tank.
One of the differences between the drain lines of the present invention and other lines, is the pipe size. In the vacuum drain system, it is possible to use only a 1/2 inch flush liquid supply line and a two inch waste drain line, which is much smaller than the four inch diameter drain lines of the gravity type drain system. This makes it much easier to initially install the vacuum-powered drain system or to have the lines brought to a new location since it permits the lines to be routed much more freely within the floor space of the airplane. Further, the vacuum drain lines do not require a constant down slope as with the gravity system, which makes the system much easier to install. The smaller diameter lines with no required down slope make it possible for the airplane manufacturer to accommodate each of the airline customer's desires; and makes it practical for each airline to arrange its galley and lavatory facilities as the need and usage dictate.
The equipment located in area 38 of the fuselage shown in FIGS. 1 and 2, also includes a pair of vacuum pumps or blowers 50, 51, which, as shown in FIG. 3, are connected in parallel to the storage tank 40 through an interconnecting tank ventilation line 48, a water separator 49 having a negative pressure relief valve 74, and branch lines 48A and 48B. A vacuum pressure bleed line, from the tank ventilation line 48, is connected to a vacuum pressure transducer 113 and vacuum pressure gage 112. The water separator 49 comprises a plenum chamber that functions to prevent liquid droplets from leaving with the airstream in the overboard vacuum vent line 54. The vacuum blower system further comprises: a vacuum blower switch 110; a pair of pressure switches 52, 53; and a pressure gage 73 connected through line 72 to the water separator 49. The vacuum blower system maintains approximately 6 to 8 PSIG vacuum pressure in the system when the aircraft is below the minimum altitude of approximately 15,000 feet or on the ground. In flight, above 15,000 feet, vacuum pressure is maintained by venting the waste tank 40 to the outside ambient air, and controlling the effect of cabin air pressure by a variable orifice.
Assuming that the airplane has been at its cruise altitude above 30,000 feet and the toilet waste disposal system has been operating on the vacuum pressure differential produced by venting the system to ambient air through overboard vent line 54, shown in FIG. 3, and now the airplane is starting to descend. At the descent altitude of approximately 15,000 feet, the vacuum pumps 50, 51 are made to cut in automatically by pressure switches 52, 53, shown in FIG. 3, and the vacuum pressure in the tank 40 is then supplemented by the vacuum pumps. When the airplane is below this altitude, or when the pressure differential is less than a predetermined amount, the vacuum pumps are put into operation. The vacuum pressure in the tank is directly sensed and is maintained at a predetermined amount. An altimeter or barometric pressure type instrument could also be used for operating the vacuum pumps. For economy, the vacuum pumps are designed and sized so that they produce an acceptable minimum level of vacuum pressure throughout the system. Therefore, even if the vacuum pumps remain in operation at cruise altitude, the system would not detrimentally exceed its vacuum pressure design level.
Also, in the unpressurized area 38 of the fuselage in FIGS. 1 and 2, the waste holding tank 40 and its associated equipment can be expected to be subjected to a wide range of ambient air temperatures, i.e., approximately minus 70° to plus 100° F; and a good thermal design of the equipment is necessary to avoid freezing. It may be that the piping of the waste disposal system could run into areas of the airplane where it is cold or from a space requirement standpoint, it may be that the best location for the waste holding tank is outside the pressure hull of the airplane; where, at cruise altitudes, the ambient air temperature can drop to minus 65° F. This is so low, that provisions have to be made to keep the lines from freezing up. Also, there is some evaporative cooling inside of the waste holding tank, that tends to further cool the waste matter. Therefore, to contend with these low temperatures at altitude: electrical heating tape is wrapped around the lines; the waste holding tank is insulated and wrapped with heating blankets; and the equipment has insulation installed around it as required. The present airplanes have heating tapes, blankets, and heating units installed around the equipment, including the water distribution system, in order to apply heat locally where the temperature drops below a certain predetermined level for maintaining their equipment at operating temperature; and the amount of heat necessary is established by calculation and tests.
It is recommended that the waste tank 40 be of a glass fiber filament wound type, with foam insulation in-between the inner layer or bladder, and the outer wrappings. Since the advantage of this construction is that it is of light weight, rigid, resistant to chemicals, and has good thermal properties; thereby, minimizing the need for protective heating. The connecting lines could be made from filament wound glass fiber, titanium, or stainless steel as is generally used on present known installations. However, the metal materials may require protection against freezing in some areas.
FIG. 3 shows in schematic form the preferred embodiment of the vacuum-powered toilet waste system of the present invention. The elongated waste holding tank 40 is positioned such that it is lengthwise and approximately parallel to the longitudinal axis of the airplane; and a low point or sump is provided by sloping the bottom surface from each end of the tank towards a low point in the longitudinal center of the tank. The waste tank 40 has a transversely oriented filter screen 55 which separates the tank into a forward compartment 40A and an aft compartment 40B to separate the solid waste particles from the filtered liquid. The waste matter from the toilet drain system enters at the top of the tank through one of the main drain lines e.g. 41, against the deflector 47 and into the waste tank compartment 40A. The deflector 47 for the incoming waste functions to utilize the impinging force flow of the incoming waste to wash along the filter 55 and prevent it from clogging up. The liquid portion of the incoming waste filters through the wire mesh screen filter 55 into compartment 40B, and from there it is utilized as the flush liquid. The positioning of the tank and its filter element are such that the acceleration forces of take-off and the deceleration forces of landing and braking, as well as the in-flight pitch attitude changes, causes the waste matter to slosh fore and aft through the filter screen 55 and thereby aids in the filtration process. Although, the tank could be positioned laterally with respect to the longitudinal axis of the airplane; however, the turns or lateral movements of the airplane are generally made with a positive 1 g. centralized force or as generally sensed by a seated passenger, a constant seat pressure; and this would induce very little if any slosh motion to the waste fluid.
The tank is mounted within the fuselage such that the waste receiving compartment 40A and the filtered liquid compartment 40B are aligned longitudinally with respect to the fuselage of the aircraft; and the longitudinal axis of the tank is aligned horizontally, approximately parallel to the longitudinal axis of the fuselage, such that when the aircraft is at a relatively high angle of attack as at take-off and during climb-out, the truck axis is likewise horizontally inclined and the liquid level in the waste receiving compartment 40A is momentarily above that in the filtered liquid compartment so that the liquid in the forwardly positioned waste receiving compartment 40A seeps through the filter separator 55 and into the aft compartment 40B due to the difference in liquid head.
Generally, in the filtration process for reclaiming liquid from the mass of paper and human waste, the paper is one of the biggest problems. It is the most difficult thing to cope with because when it gets wet, it disintegrates and reverts to pulp; and in so doing, makes very small particles that will pass through even a fine filter. It clogs up the filter elements; and lodges in cracks and crevices, where it starts decomposing and causing an odor.
The glass fiber filament wound tank has been in use in aircraft for toilet systems, and some of them have filter units in them. These tanks have generally had a small pump filter unit that was incorporated within a recirculating gravity type toilet tank system; and wherein, the small pump filter unit was submerged into the waste matter. Every time the toilet was operated through a flush cycle, the pump started up and drew through the small filter unit, comprising a scraper and basket, a large quantity of flushing fluid in a short duration of time. Also, some of the aircraft manufacturers have moved the waste holding tank portion of their recirculating gravity type toilet tank units below the floor level; and in some instances, have the toilet portion draining into a single large waste holding tank situated below the floor level; wherein, one or more filter pump units are submerged into the waste matter in the holding tank. The known pump filter assemblies for the recirculating gravity type toilet tank units basically comprise a number of disks with scrapers in-between. The disks are spaced apart approximately five hundredths of an inch or so and the scrapers in-between, keep cross-pockets from being drawn into it. However, there is a problem with cloth and plastic materials getting in between the disks and scrapers, and jamming the filter assemblies. In addition, they don't provide the degree of filtration desired for a vacuum waste disposal system as the present invention, for getting the recirculating flush liquid clean. Further, the known pump filter assemblies are started up and operated on demand; whereas, in the present invention, the filter unit is in constant use and of the static type, which produces a much finer filtration.
In general, the filtering element 55 used in this invention is of the small mesh type that looks somewhat like a household fly screen. The filter screen should be of approximately 20 mesh (20 openings per inch) with at least 50% free opening area i.e., the wire gage size of the screen should be limited such that at least 50% of the screen area be free opening and not obstructed by the thickness of the wire. The approximate 20 mesh screen element must be sufficiently backed up structurally by a strong grid on both sides thereof, in order to support the waste slosh loads imposed thereon. The required screen filter area is approximately 2.5 square inches for each gallon of storage tank capacity. The filter 55 is different from the type of filter generally in use in the waste systems of passenger carrying commercial airplanes, in that it does not have scraper blades or similar means for removing entrapped sludge that accumulates against the screen mesh; and no large volume of fluid flows through the filtering element 55, as with those of the prior art, during a short period of time. Instead, the filter assembly 55 of this invention, is a trickle type that allows the fluid to trickle through it. The fluid becomes relatively clear of particles because of the fine mesh screen element that retains the paper particles or pulp. The retained paper particles build up against the interior wall surface of the fine mesh screen element and produces a sort of filter cake of the paper itself that aids in the filtration process i.e., the screen provides a matrix for the disintegrated paper and forms a filter cake that actually aids in the filtration process. Whatever small amount of paper that does get through is of such small particle size that it goes through the system with the reclaimed fluid without clogging up the valves in the system; and returns with the human waste and flush water again. Therefore, it is a self-cleaning type of process. Also, during the draining operation, the filter element 55 will be cleaned through a back-flushing operation; wherein, the filtered fluid in waste tank compartment 40B upon removal of a drain plug 57 or actuation of a dump valve in waste tank compartment 40A, will flow back through the screen mesh 55 dislodging the entrapped particles and wash it clear.
The shape of the filter assembly 55 will depend in large part upon the particular installation and the physical space available for the storage tank 40. However, at least half of the volume of the storage tank 40 should be on the unfiltered side 40B of the fine screen filter element because any waste matter that does not dissolve completely will have to remain within the unfiltered compartment 40A until the storage tank 40 has been drained out; and the remaining storage tank volume would be for the basically clean fluid that has been filtered. In addition to the central waste holding tank 40, there is another smaller tank or accumulator tank 58 which takes some of the filtered liquid that has passed through the static filter unit 55 into the flush liquid chamber 58A, and retains it under pressure for the next flush cycle.
The accumulator 58 comprises: a bladder or diaphragm 59 separating it into a liquid compartment 58A and an air compartment 58B; an air valve 68 through which the air compartment 58B is pressurized and a pressure transducer 69 which transmits the accumulator pressure from air chamber 58B, through line 70, to a pressure read-out gage 71. The pumps 62, 63 are actuated by the pressure switches 66, 67 and operate only on demand to fill the flush liquid chamber 58A of accumulator tank 58.
The filtered liquid from waste tank compartment 40B is withdrawn from the tank sump through a pair of parallel lines 60, 61 by impeller pumps 62, 63 through check valves 64, 65 and into the accumulator tank 58. By positioning the outlets of the lines 60 and 61, at the bottom of the tank or tank sump, any solids passing through the filter 55 will be withdrawn and recirculated back to the waste receiving side of the filter for refiltration, thereby preventing build-up of sediments and paper mache from the tiny pulp particles, in the filtered liquid compartment 40B. If this is not done, i.e., if sedimentation is allowed, as in some designs, the system would become inoperative after a period of usage. For example, of the outlets for withdrawing the filtered liquid were moved to a higher location on the tank compartment 40B, the sediments including the paper mache, would build up from the bottom of the compartment and gradually decrease the flush liquid storage capacity. Also, this sediment would break up and chunks would become loose and be drawn into the flush system where it would clog the pumps, valves, spray ring, etc., and eventually make the system inoperative.
When the pressure switches 66 and 67 sense low pressure in air chamber 58B due to the flush liquid chamber 58A being emptied, they actuate the pumps 62, 63 to refill the accumulator tank chamber 58A where it is retained under a pressure of approximately 30 to 45 PSIG until it is used for flushing.
The schematic of FIG. 3 as an optional feature shows the wash basin 75 having a drain valve 76 connected to a trip handle springloaded shut 77 and drain pipe 78. The wash basin overflow liquid enters line 79 and passes through a vacuum braker 80; and from there, through line 81 to enter into the toilet fixture 84. The wash basin drain valve 76 when operated by trip handle 77, directs the wash basin water through line 78 to enter a branch line 41A of the main drain line 41. The toilet fixture 84 which is generally covered by a decorative shroud, comprises: a lid 85, a seat 86, a bowl 87, a spray mechanism or ring 88, flush valve 91, vacuum control valve 97 and actuator 92, trip handle and timer mechanism 93, and flush fluid valve 94.
The flush fluid valve 94, flush drain valve 91, actuator 92, and the toilet flush timer mechanism 93 should all be vacuum and/or electrically controlled and powered. To determine whether enough vacuum pressure would be available just downstream of the flush drain valve 91 during the flushing operation, test readings were made approximately six inches below this valve, and it was found that the vacuum pressure decayed too rapidly to function for this purpose. Therefore, it was necessary to provide auxiliary means, such as to vacuum pressure charge a tank 98 between the flush cycles for the vacuum reservoir and to draw on this energy for operation of the mechanical components.
The bowl overflow sensor 89 will put a signal through the timer 93 to the vacuum control valve 97 and actuator 92 causing this to automatically open valve 91 for 3 seconds to prevent liquid from overflowing the bowl.
A continuous ventilation (not shown) of the air around the toilet bowl is provided to make certain that any odors at the toilet or within the lavatory compartment are removed and vented to the outside of the airplane. The vacuum waste drain line 41A, from the flush drain valve 91 below the toilet bowl, runs through a shut-off valve 95 and into the top of the central waste collection tank 40, where it is directed by deflector 47 against the filter 55 to wash it and prevent it from clogging up.
An automatic valve 100 is installed between the branch drain lines 41A, 42A, 43A from the individual lavatory unit drains and their connection to one of the 2 inch diameter main or trunk drain lines 41, 42, 43. This automatic valve 100 will open only when there is liquid present in floor drain branch line 101 to be drained; and is also required to prevent too great a load on the vacuum pressure of the system, such as would occur with a large number of open drains. This automatic valve 100 also prevents any back flow of odors through the floor drains connected to line 101, when the system is shut down or when on the ground. As depicted, the automatic drain valve 100 could serve as a junction for the connection, as through line 101, of additional individual lavatory units.
The main drain lines 41, 42, 43 are brought into the top of the waste holding tank 40 instead of at the bottom in order to prevent backflow into the lines when the aircraft attitude is such as to position the holding tank above the toilet bowls, and to prevent sediments at the bottom of the tank from clogging the inlet. The central waste collection tank 40 serves two functions: as the storage receptical for the waste from the toilets and galley 37; and as a vacuum pressure accumulator for the differential pressure flow, required to move the waste matter through the drain lines. It may be desirable to add an additional vacuum pressure accumulator into the system for those occasions where the waste holding tank is nearing its full capacity.
The operation of the vacuum-powered toilet flush system is as follows: After waste matter is deposited into the toilet bowl 87, the flush cycle is activated by depressing the toilet flush lever 93, which actuates a timing mechanism. This timing mechanism is connected through line 96 to vacuum control valve 97 for controlling the flush valve actuator 92. The flush valve actuator 92 is vacuum powered by a vacuum reservoir tank 98 which bleeds vacuum pressure from main vacuum drain line 41A, through check valve 99. The flush valve actuator 92, when actuated by the toilet flush lever 93, opens up both the flush drain valve 91 at the base of the toilet bowl and the flush liquid valve 94; thereby releasing recirculated flush liquid out through the spray ring 88 into the upper section of the toilet bowl 87 to cleanse the toilet bowl. Approximately one quart of flush liquid is directed down the toilet bowl through the spray ring 88, such that the sides are kept clean and the paper seat cover and other paper is moved to the bottom of the toilet bowl, where it will be caught in the air stream and flushed away. The waste matter and flush liquid are removed from the toilet bowl by the vacuum pressure applied through the flush drain valve 91 and directed into the branch drain line 41A and main drain line 41, from which it enters into the central collection tank.
The flush liquid valve 94 and the toilet waste valve or flush drain valve 91, are linked or coupled together so that when the flush lever 93 is tripped, both of these valves open up: one to allow outflow of the waste matter; and the other to let in the flushing or cleaning liquid. The valves 91 and 94 will remain open for the approximate 3 second duration of the cycle. The duration of the flush cycle can be changed by adjusting the timer 93.
Operation of the system is not dependent upon the use of a liquid. It should be noted that the unit will function almost equally well if no liquid were used during the flush cycle, as the pressurized cabin air alone, will direct paper to the bottom of the bowl; and the waste matter could still be removed from the toilet bowl and moved through the waste lines to the holding tank 40 by the air flow alone. However, the liquid is necessary to make the system sanitary; because, it is utilized for washing down the toilet bowl to remove any smearing substance that might otherwise cling to the sides and be left in the toilet bowl, causing odors. In addition, the liquid aids in depressing and compacting the waste matter. The flushing action or flow of the liquid from the toilet bowl through the drain lines also aids in the efficiency of waste removal, by slightly inducing a suction effect in the tubing, in a manner similar to that induced in a gravity feed system. The bowl interior should be smooth and with as non-sticky a surface as possible.
The main purpose in producing a vacuum is to be able to remove the waste matter from each of the toilet compartments and transport it through the drain lines to a central holding tank where it can be processed and simplify the servicing of the airplane. During flight at altitudes above 15,000 feet, there is sufficient differential pressure between the aircraft cabin pressure and ambient, to provide a pneumatic vacuum source of infinite capacity, when the central waste collection tank 40 is vented through overboard vent line 54, to the outside or ambient atmosphere. Therefore, there is no problem in the number of toilets that are simultaneously flushed. However, when the aircraft is below this altitude or on the ground, where this pressure differential is to be supplied by a blower system, a pneumatic vacuum reservoir is required to provide the capacity for normal operation of the system, or the capacity of the storage tank should be large enough to provide the vacuum capacity.
The vacuum pumps 50, 51 are put into operation when the pressure in the tank 40 drops below a predetermined value. In flight, the pressure differential between the inside and the outside of the airplane is sufficient to prevent the vacuum pumps from operating.
The vacuum flush cycle is operative anywhere from a 6 psi pressure differential to the maximum that is available, which is about 7 to 9 psi. For the Boeing 747 above 35,000 feet altitude, the maximum pressure differential is approximately 8.9 psi. This amount of pressure differential available is as a result of the altitude at which the aircraft is flying, in combination with the degree of cabin pressurization. When the airplane is on the ground or below an altitude giving a pressure differential of less than 6 psi, a forced flow has to be produced by a pump; and since the system is operative at a 6 psi pressure differential, it would only be necessary for the pumps to supply this amount.
The system is designed such that it is capable of handling a great many of those unexpected things that happen; i.e., in the event that every one of the individual lavatory units, which are dispersed throughout the aircraft, were to be operated through their flush cycle, not in a sequential manner, but at the same time, there would be no damage done to the system. However, the result will be that a much greater than normal pressure drop will take place across each of the individual toilet units. If the waste matter were to move as a neat plug through the lines, there would hardly be any effect on the vacuum pressure; since it would just be the volume of air in the tube that would be displaced. However, that is not the manner in which the system generally functions. Actually, the waste matter often strings out and a lot of air blows by the waste, which drops the pressure; and if there are too many of the lines open at the same time, the flow of the waste could stop. Therefore, the system is basically restricted by the usage as opposed to number of lines going into the tank. Although it is quite remote that every toilet unit would be flushed at the same time; it could happen, which would cause less efficiency in the flow of the waste matter and could prevent the waste from reaching the tank during the flush cycle. A simple, computed simulation program was written on the probability of simultaneously flushing, using "Poisson" distribution.
The program accepted input for:
n = number of toilets (13)
T = occupancy time (180-300 sec.)
Tf = flush time (5 sec.)
The program picked random numbers in the range of the occupancy time. One computer experiment was to check into the system at any given time and register activity of that moment. One hundred thousand experiments were carried out, assuming that all toilets were being occupied, with one flush per usage cycle.
Result:
______________________________________0 units flushed 70.500%1 unit flushed 24.900%2 units flushed 4.180%3 units flushed 0.400%4 units flushed 0.003%5 units flushed 0.000%______________________________________
The waste matter doesn't have to move the entire distance to the holding tank 40 during one flush cycle. Generally, the waste matter will flow rapidly enough through the lines so that it will move the entire distance from the toilet bowl 87 into the holding tank 40 during one flush cycle. The waste matter continues to move in the line after the flush valve 91 has closed, due to the differential pressure between that section of the line downstream of the waste matter and that section of higher pressure spectrum thereof until the pressure in the waste line and the holding tank has become equalized. However, if it doesn't, there is no harm done if the waste matter stops in the line or moves intermittently through the line, since it will eventually wind up into the tank. Normally, the next flush cycle will then push it the remainder of the distance to the tank,
FIG. 4 graphically illustrates for a given set-up, the correlation between the initial vacuum tank pressures in inches of HG, and the flow velocity in ft/sec. The waste material consisted of: four feet of toilet tissue, a twelve inch dog food extrusion, one paper seat cover, and one paper towel. The flush time was determined from the time that it took to empty the bowl, and to transfer the waste material through the lines to the holding tank. This was a function of the pressure differential between the inside of the collection tank and the toilet compartment; and a further determining factor, was the quantity and consistency of the waste material. As can be seen, it varied between 352 ft/sec for the dry matter at 20 inch HG vacuum to 40.5 ft/sec for wet matter at five inches HG vacuum. The wet matter at 10 inches HG vacuum, attained a velocity of 61 ft/sec half of which is considered satisfactory for design purposes. In flight, the pressure differential will be greater, which is good. For example, assuming that the longest tube run is 120 feet, the time required to clear the tube should be less than the flush cycle. Using a pinch-type flush valve, the following criteria should therefore apply for design purposes: closed to open -- 1 second; stay open -- 1 second; open to close -- 1 second; total time of valve cycle -- 3 seconds. Most of the acceleration of the waste material in the tube takes place almost at once and the speed is almost constant for the remainder of the distance to the holding tank. As previously stated, the waste matter does not necessarily have to move the entire distance to the waste holding tank during one flush cycle; but can be moved to the waste tank by a series of flush cycles.
FIG. 5 illustrates graphically for the same given set-up, the decay rate in the vacuum pressure of the holding tank, during the dry and wet matter flush tests, as plotted against the initial vacuum pressure in the holding tank before each flush operation. The remaining vacuum pressure in the holding tank is therefore the differential between these two values. For example, to find the remaining vacuum pressure in the holding tank after each flush, subtract the decay from the initial (i.e., initial, 10 inches HG; decay, 8.7 inches HG; remaining vacuum pressure, 1.3 inch HG). In comparison with the dry matter flush tests, the decay rate in the vacuum pressure during the wet matter flush tests is much less due to the sealing of the water in the lines. For example, for the wet matter at 10 inches HG initial pressure, the decay is only 4.8 inches HG and the remaining vacuum pressure is 5.2 inches HG; whereas, for the dry matter at 10 inches HG initial pressure, the decay is 8.7 inches HG and the remaining vacuum pressure is 1.3 inches HG. A high capacity, high pressure differential pump is required for maintaining the required vacuum pressure inside the collection or holding tank while the aircraft is on the ground or at low altitudes. For design purposes, to establish the decay rate of vacuum pressure during the flushing operation, a pressure transducer can be utilized and installed in the holding tank. The air consumption during testing using a 100 gallon tank was approximately (100 × 8.7) / (7.5 × 29.92) = 3.86 scf (standard cubic feet) of air for a flush valve opening of 1.5 seconds. For a full three second flush cycle, where the opening takes 1 second and the closing takes 1 second, approximately 5 scf of air will be required. In estimating the pump capacity required for a passenger aircraft the size of the Boeing 747, having a complement of 16 toilets, and assuming that a toilet will be flushed every three minutes would therefore give an average of (3 × 60) / 16 = 11 seconds between flushes. To cover the total consumption of air, the blower must therefore be able to supply the following: flushing (5 × 60) / 11 = 27 scfm (standard cubic feet per minute), plus a reasonable allowance for leakage of approximately 7 scfm. The total pump capacity required is therefore 34 scfm. A pump of this capacity should therefore be able to maintain a vacuum pressure differential of 10 inches HG.
FIG. 6 graphically illustrates for the given set-up, the acceleration test of wet matter to determine the acceleration rate of wet matter from a static condition at the flush drain valve 86 to its entry into the waste holding tank 40 positioned approximately sixty feet from the toilet bowl. The test results established that the wet waste matter obtains 82% of its average velocity within three feet of the flush drain valve 91.
FIG. 7 graphically illustrates for the same given set-up, the effect that a varying amount of matter has on the flow velocity when the pressure is kept constant. (In the illustration of FIG. 4, the amount of waste material used was considered to represent an average value.) The conditions of the mass versus velocity graph in FIG. 7 were: 15 inches HG vacuum initially in the holding tank; and varied amounts of water during the flush operation wherein the water was poured directly into the bowl prior to flushing. As expected, the transfer time is increased, with an increase in mass; however, the total time of a 3 second valve cycle for a maximum tube run of 120 feet, as established in the preceding FIG. 4, is a realistic value for design purposes.
FIGS. 8 and 9 relate to the tests that were conducted to establish the sizing of the toilet bowl air vents 90 or the peripheral air gap required between the toilet bowl 87 and the shroud to prevent any dangerous suction from forming if the toilet is flushed with a person sitting on it. FIG. 9 shows a plastic toilet seat lid 85 that was constructed for the negative pressure tests with five pickup probes inserted as follows: four of the probe pickups were located one inch inside of the toilet bowl rim; and the fifth probe pickup was located in the center of the seat lid. The initial tests indicated that the readings were approximately the same at all locations; therefore, subsequent test readings were taken from the center probe pickup only. Tests were conducted with varied, predetermined air gaps between the lid and the toilet bowl rim. However, because the rim of the toilet bowl was uneven, the air gap was measured with its maximum and minimum dimensions for each of the tests run. The tests were run dry with no waste. The test results established that a vent of a half-inch gap around the top of the toilet bowl will provide completely safe conditions; and that this amount of gap should therefore be used for design purposes. It should be noted that this air gap or vacuum break must be an integral part of the toilet fixture because of the possibility of a person sitting directly onto the toilet bowl without the use of the seat.
For servicing an airplane equipped with this invention, referring to FIG. 3, the procedure is to remove the drain plug 57 and drain out the waste matter from the storage tank 40. When the storage tank 40 is drained, the waste matter sludge is removed from tank compartment 40A; and as it is removed, the relatively clean filtered fluid in tank compartment 40B flows back through the fine mesh screen of the filter 55 and in so doing, back-flushes the filter 55 and washes it clean.
For back-flushing, the check valves 64, 65 can be overridden by pulling on lever 102 interconnected thereto by control cable line 103, to allow backflow and the accumulator tank 58 is emptied; thereby supplying additional pressurized fluid for cleaning the filter 55. Alternatively, the fluid in the pressure lines 44, 45, 46 and the accumulator tank 58 could be left in; and in that way, the system would remain primed for operation.
If necessary, it would be satisfactory to just remove the drain plug 57 and remove the sludge accumulated within tank compartment 40A and then reinsert it and fly again; because enough initial liquid would be retained in the accumulator tank 58 to recycyle the system.
But in time, because the liquid gets little by little more contaminated, it is desirable at certain intervals to also drain the pressure side of the system, including the accumulator tank 58. This is accomplished by actuating the check valves 64, 65 by pull lever 102 through the control cable 103, so that the check valves 64, 65 are overridden; thereby, permitting the fluid in lines 44, 45, 46 in the pressure side of the system, to flow back through the pumps 62, 63 into the interconnecting lines 60, 61 to the storage tank 40 where it back-flushes the filter 55 and goes out through the drain emptying into the tank truck (not shown). Also, the lines 44, 45, 46 of the pressure side of the system can be drained out by opening the pressure drain valve 104.
After this has been done, it will be necessary to fill and recharge the system. This is accomplished by injecting clean liquid from the servicing vehicle through the fill tube 105 or connection 106 on the pressure drain valve 104. The fill tube 105, as shown, does not go through the waste receiving compartment 40A; but is routed around the tank to enter at the top and the fill tube exit is positioned such that the liquid ejected therefrom impinges along the filter 55 to wash it clean as the storage tank 40 is filled. To fill up the storage tank 40 through connection 106 on, the pressure drain valve 104, the check valves 64, 65 are opened through actuation of pull lever 102 and control cable 103 and the clean liquid is caused to flow into and back through the pumps 62, 63 into the storage tank 40 via lines 60, 61. The pressure side of the system line 44 is primed and recharged by closing of check valves 64, 65 and drain valve 104, and then starting the pumps 62, 63 until the accumulator tank 58 is filled with the clean liquid.
A storage tank fill quantity gage 108 is connected to a capacitance sensor 107 that is imbedded within the glass fiber wound construction of the tank wall in order that it does not come in contact with the waste. The capacitance sensor element 107 comprises a strip or a belt of electrically conductive material and by building it into the tank wall, there is less chance of it becoming contaminated by the waste.
The required storage capacity of the waste tank 40 is determined by the frequency of servicing. For a typical Boeing 747 airplane with daily servicing of the system, ample tank capacity would be approximately 200 gallons.
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A vacuum flush waste diposal system for aircraft; wherein the required vacuum is acquired at altitude through the differential pressure between the aircraft cabin pressure and the ambient pressure above approximately 15,000 feet. When the aircraft is below this altitude or on the ground, the vacuum is provided by a blower. For flushing the toilet bowl, a timing device is initially actuated and functions: to introduce a recirculated flush fluid into a flush ring in the upper portion of the toilet bowl; and to open a drain in the lower portion of the toilet bowl, leading to the vacuum waste line; whereby, the waste and flush water are rapidly propelled through the waste line towards a centrally located holding tank, by the differential pressure acting upon it. Once in the holding tank, the waste fluid is filtered out for further use as the recirculated flush fluid.
The holding tank is positioned within the fuselage of the aircraft and has a vertically oriented filter screen separating the tank longitudinally into a fore and aft compartment, so that the acceleration forces of take-off and the deceleration forces of braking upon landing causes the fluid to slosh fore and aft through the filter screen to aid in the filtration process.
The toilet bowl incorporates integral air slots around the periphery of the toilet bowl so that there is no possibility of inadvertant injury to the user that could be caused by the sudden application of vacuum pressure to a seated occupant.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. application Ser. No. 09/752,925 filed Jan. 2, 2001, which is a nonprovisional of U.S. Provisional Application No. 60/173,980 filed Dec. 30, 1999. The contents of both applications are herein incorporated by reference in their entireties.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention generally relates to data processing systems and methods for managing a complex television episode development and production. More specifically, the present invention relates to the systems and methods for creating feedback controlled productions of television episodes wherein information is collected from viewers through a sophisticated processing network including Internet and web based collection sites.
[0004] 2. State of the Art
[0005] Since its inception in the 1940's, television has entertained by methods including the presenting of fictional stories, which have typically been developed by an individual writer or team of writers with no audience feedback. Television is such a successful entertainment medium that it has penetrated practically every North American home. Despite the unrelenting encroachment of television into the everyday lives of the general population, writers of episodic shows and situational comedies have been and continue to be constrained to create their art prior to receiving any indication of public acceptance or other feedback. The advent of internet technology provides means for obtaining immediate audience feedback, which can be used to pro-actively adjust the coarse and subject of the television show to enrich story development.
SUMMARY OF THE INVENTION
[0006] The invention represents convergence technology that works to incorporate audience feedback into later episodes to enhance the quality and audience acceptance of later shows by both broadening scripting possibilities and fulfilling audience expectations. Engendering audience participation will allow ready access to audience information, heightening the ability to effectively target future merchandising opportunities.
[0007] Akin to several contemporary television shows (e.g., Buffy The Vampire Slayer, The Bold And The Beautiful, etc.) the method of the present invention presents questions to the audience on its custom-designed “sister” internet homepage. Similar to the Internet “teaser” website developed to promote the recent Blair Witch Project movie, the “sister” homepage will also act to assure future audience attendance by displaying some limited information about upcoming episode(s). The present invention, however, utilizes its sister website to do more than simply poll or inform its audience. First, the type of question asked by the invention is distinguishable from those generally found on television shows' websites today: namely the invention queries will be prescribed to directly determine the show's story line, whereas the latter's are for more general individual quizzing, entertainment or indirect information gathering for the show's producers. Second, during each episode the intention's sister homepage will be updated simultaneously to reflect the events that transpired during the story. Third, the method of the invention incorporates and utilizes planned, systematic data gathered from audience feedback for creative and commercial purposes.
[0008] The purpose of the invention is to create shows that significantly reflect audience preferences. After the televised airing of the weekly TV or other show, the show's sister website will poll the audience to determine the direction that the storyline should take in future episodes. Audience members can also participate in the polling via toll-free 800, 877 and 888 numbers, Personal Digital Assistance (“PDAs”), email or by fax. The weekly poll will close after several days, at which time the TV production staff will finalize its incorporation of the audience feedback into various future episodes, with results appearing on air as early as one week later. Audience feedback that influences programming content may be collected directly from weekly audience polling, content-driven audience-authored email, chatroom discussions or Bulletin Board Services (“BBS”) postings, and other forms of viewer online participation (e.g., games, contests). Feedback also may be surmised from audience-preferences garnered from intelligence data collected from the story's e-commerce character-portals residing on the sister website.
[0009] The invention satisfies a yearning for entertaining interactivity by introducing new techniques to maximize the convergence of the extant static television scripting practices and of developing internet technologies to create a new paradigm for interactive entertainment. The invention enables delivery by exact, widely available, technology of content-rich “narrowband convergence” story telling experience.
[0010] The invention creates a link now missing in interactivity, namely, actualization of audience input in a product created by a production company for audience consumption. Under the invention, the audience now is an active participant in content production anticipated for its own consumption, by putting in place viewer-to-producer information sharing infrastructure.
[0011] Furthermore, the TV show acts as an innovative backdrop for modern e-commerce, by serving as: a “catalog” for online merchandising, a vehicle for product placement commercials, and, its website, as a repository for market intelligence. Enhancement of viewer ownership in the show's storyline will increase the audience's “stickiness” and allegiance to televised airing and the website's e-commerce activities. And because the e-commerce is being developed simultaneously with the show, both will be more organically integrated, and therefore, more seamless to the end-user. Viewer ownership would be a powerful tool for driving traffic across media platforms, opening new doors for user retention and leveraging. Transitioning the passive TV viewer into an active Web user enhances brand awareness and increases advertisers' exposure. A viewer invested in his/her story's content will become and remain attracted to the advertising and e-commerce opportunities associated with such content.
BRIEF DESCRIPTION OF THE FIGURES
[0012] FIG. 1 —Schematically portrays interrelation of audience, programming staff and internet.
[0013] FIGS. 2 a and 2 b —Diagrams comparing methods of receiving audience feedback.
DETAILED DESCRIPTION
[0014] Although the preferred embodiment set out below demonstrates means for production of a television show, the invention is suitable and readily applicable to all media scripting, including, but not limited to, on-line streaming media, film and other visual/format(s) for storytelling. FIG. 1 is a schematic representation of the interrelation between the audience/viewers ( 10 ), production staff ( 11 ), broadcast company ( 12 ), internet and other methods of communicating with the audience ( 10 ), web portals/web producers ( 14 ), data vendors and advertising media ( 15 ), and the sub-components thereof.
[0015] The audience/viewer ( 10 ) component consists of the typical nationwide market, which receives data by way of transmission to television sets ( 16 ) via broadcast over open airwaves, encoded broadcast, and cable subscribers ( 17 ). Broadcast by way of transmission of signals over open airways and encoded broadcast is a unidirectional media. In contrast, audience members receiving the television transmission via cable and satellite network are increasingly choosing to utilize the broadband capability of the cable interface to enable bidirectional data exchange. A common mechanism for facilitating bidirectional transfer is the set-box ( 20 ), commonly known by one brand name WebTV. Of course, internet service providers (“ISPs”) ( 19 ) provide internet access to customers who do not have a set-box ( 20 ) applications. Presently, it is more typical for customers to access the internet by way of modem connected to standard or dedicated service line (“DSL”) telephone company line ( 18 ). Although interact access is the most ready method of obtaining audience feedback, alternate methods of obtaining audience feedback are provided and have the audience use specified toll-free 800, 877 or 888 number(s).
[0016] Production staff ( 11 ) is made up of the producers ( 24 ), director ( 23 ), editor ( 23 a ), writing staff ( 21 ), web master/producer ( 22 ), and support staff, collectively the production staff. The web master/producer ( 22 ) acts as the liaison between the computer programming personnel that operate the web portals ( 14 ), the on-air staff, namely, the “writers” ( 21 ), the director ( 23 ) and editor ( 23 a ).
[0017] The web portals ( 14 ) consists of typically automated means to monitor the audience participation and feedback. Managers of the web portals ( 14 ) consider requests from data vendors ( 15 ) and production staff ( 11 ) in their development of monitoring function and in the manner of tracking audience characteristics. The web portals ( 14 ) also have the responsibility for designing webpages that present to the audience queries received from production staff ( 11 ) as well as advertisements received from the data vendor ( 15 ).
[0018] A privacy monitor ( 25 ) is recommended to comply with federal child privacy protection statutes and other laws to ensure that audience loyalty and comfort is not sacrificed for myopic commercial gain.
[0019] The data vendor/advertiser interface ( 15 ) seek to leverage the continuous, typically real-time, information that is available from web portals and other means of gathering audience feedback.
[0020] A. Show Production
[0021] A.1 Overlapping Audience Questions:
[0022] Audience buy-in will not be obtained without the production staff ( 11 ) being able to include, in as timely a fashion as possible, the feedback received from the audience. This requires a careful pre-selection of questions and understanding how responses to each type of question will be incorporated into the developing script.
[0023] The preferred embodiment will present questions to the audience (“end user”) by way of a multi-tier system based on when each tier of questions can be integrated chronologically into the story. For example, responses to some of such questions can not and will not affect future shows airing as late as four weeks later (i.e., episode 4). It will not be apparent to the audience that a particular question can or cannot be immediately incorporated into the story due to this tiering of questions, and the segregation of questions between various character portals.
[0024] Examples of the tiered-based questioning of this invention are: the Editor-Driven Query (EDQ), Director-Driven Query (DDQ), Writer-Driven Query (WDQ) and the Online Request (OR). The EDQ, DDQ and WDQ are designed to elicit responses that can be utilized in various shows that will air from two to four weeks from questioning. The OR is a story-driving vehicle that is solicited from audience email, chatroom discussions or BBS postings, and is designed to air within one week from posting. The EDQ, DDQ, and WDQ questions are drafted by the show's staff, whereas, the OR is storyline-content that originates within the audience's imagination and then later is culled and incorporated by the staff into the show's storyline. Further explanation of this multi-tiered system is set out in Table 1, below.
[0000] TABLE 1 1. EDO—Editor-Driven Scene/Query: 1.1 Added to the show's production the second to last day of principal editing. 1.2 Borrowing from the news show production style, this scene will involve limited characters and simple locations. 1.3 Generally, short in duration 1.4 Can serve as a foundation to future plot changes. 1.5 Can be accomplished by shooting alternative endings in principal photography (two weeks earlier) and placing the responsibility upon the editor to actualize the story's direction during assembly. 1.6 A second means to accomplish the same event would be to shoot the voted upon scene after the completion of principal photography, during post-production. Although the story's direction is not “actualized” by the editor per se, the onus to anticipate the later addition of footage is still upon the editor. 1.7 Airs two weeks after audience dictation. 1.8 This type of question generally will be geared more towards char- acter choices, of the “yes or no” variant (e.g., should she or shouldn't she) 2. DDQ—Director Driven Scene/Query: 2.1 Added to the Show's production during its preparation prior to shooting. 2.2 Director-driven change, (e.g., prop selection, actor choices). 2.3 Can serve as a plant for future pivotal moments. 2.4 The answer to this question generally will result more in a noun or adjective (e.g., manifesting itself in a prop or type of prop). 3. DQ—Writer Driven Scene/Query: 3.1 Effect the basis of that episode's direction. 3.2 Primarily derived from staff's answer road map and character algorithms. 3.3 A more complex answer that will generate a new subplot or fuel a former one, carrying on through subsequent episodes. 4. OR—Online Requests: 4.1 A vehicle that allows any audience member to participate in the storywriting via volunteered content sent to the show through email, chatroom discussions or BBS. 4.2 Such storyline must fit within the larger story context, and may or may not be expanded upon in future episodes. 4.3 Can be added to the show at the end of its future-lock up to its post- production.
Below are example questions for EDQ, DDQ and WDQs.
[0000]
TABLE 2
Example Audience Questions:
Story Recap: We are 8 weeks into the television season. Gwen, a vivacious lawyer, and Bart,
a NFL benchwarmer, recently have ended their 8-month relationship, due to Bart's
wandering eye and Gwen's workaholic behavior.
Gwen's Fan Questions for Week 9:
1.
“Why does Gwen want to reconcile with Bart?”
So she can seek revenge on him after she's lulled him back
Because she is now really interested in experiencing the two-way, “open” relationship
he offered her before
She's pregnant
5.
“What is Gwen's favorite color?”
Red
Green
Plum
Blue
Bart's Fan Questions for Week 9:
3.
“Should Bart give Gwen a second chance?”
Yes
No
Those who answer “Yes” will then be prompted to answer the following question:
5.
“Why should Bart go back to Gwen?
She's a convenient lay and keeps his house clean
He needs a front for his homosexual lover
Go back to her? He's just hungry and she offered to pay for dinner. Besides, her
“upper deck” is always entertaining.
Those who answer “No” will then be prompted to answer the following question:
5.
“Then who is going to do Bart's laundry while playing “French Maid?”
Bart should hire a real housekeeper
Gwen's friend Betsy
Tell me, does the team's new rookie look French to you?
Two days later, the audience answers are tallied and the most popular answers are as follows:
How Week 9's Answers Are Handled
Editor Driven Query (EDO) Scene:
Episode 11's scene answering the EDQ “Should Bart give Gwen a second chance?” was shot
two weeks earlier, with two endings.
Scene “Answering Machine Dilemma”: Bart walks out of the shower into his living room,
hearing for the first time Gwen's voice talking on his answering machine.
Ending 1 - Yes, give her a second chance.
Ending 2 - No, don't give her a second chance.
Bart walks over to his telephone, picks up the receiver and says hello.
Bart walks into his bedroom, leaving Gwen babbling into the machine.
Two weeks later the audience votes for Ending 1. The show is now in the hands of the
Editor who is instructed to use Ending 1 for the “Answering Machine Dilemma” scene. The
Editor discards Ending 2.
Director Driven Query (DDQ) Scene:
While Episode 11 is being edited, Episode 12 is being prepared for principal photography.
Episode 12's scene answering the Director-Driven DDQ question “What is Gwen's favorite
color?” is being prepped for shooting by the Director's team (which includes Wardrobe and
Props). The Assistant Director is instructed that the answer to the DDQ is “Blue” and that
she and the appropriate crew members should fill in scripts blanks accordingly.
INT. SOHO DRESS SHOP, DAY
Gwen debates between a slinky black dress or a softer, more conservative one.
After taking a deep breath, she sharply turns to the salesgirl and asks:
GWEN
Which one is sexier?
SALESGIRL
Girl, the black one.
GWEN
Then I want this one. (She holds up the dress.)
He's not worthy of eye candy . . . not yet. Besides is my lucky
color . . . and I need all luck I can get.
This information about Gwen (that blue is her favorite color) will become part of her
personal biography and weave itself into future episodes at pivotal moments (as well may her
blue dress).
Writer Driven Query (WDQ) Scene:
While Episode 11 is in editing and Episode 12 is in preparation for principal photography,
Episode 13 is with the writing team. Episode 13's WDQs are “Why does Gwen want to
reconcile with Bart?” and “Why should Bart go back to Gwen?”. The answers are,
respectively: “So Gwen can seek revenge on Bart after she's lulled him back” and “Go back
to her? This is just a free dinner with a view of her upper rack.” The writers than create a
dinner scene involving Gwen's conservative blue dress, a disappointed, “viewless” Bart, and
Gwen try to worm her way back into Bart's life and apartment. Bart shows no interest and
the evening ends with the two of them waiting for the other to pick up the check.
A.2 Production Deadlines:
Traditional television shows (both episodic and situation comedy) require minimally 6 to 8
weeks from script writing to air date. Several elements of this process that materially impact the
duration of product are:
shooting on film (additional development time) vs. video (developed in camera),
shooting on location (cast and crew movement, set decoration and location scouting)
vs. on a set (stationary workplace), and single camera (found in location shoots and
episodic shows, editing done else where) vs. multiple or three cameras (used with
sitcoms and soap operas, allows for simultaneous editing).
[0025] Television is a highly unionized industry and personnel carry out fast-paced, but regular working hours, generally with Saturday and Sundays off. Same day (or even same week) shooting and airing of televised material is relegated primarily to news, magazine and live shows and certain MTV programming. Table 3, below, outlines the most time consuming tasks associated with episodic and sitcom production.
[0000]
A. Traditional Episodic Schedule (excludes weekends)
1.
4-10 days writing a one (1) hour show.
2.
8 days prep (rehearsal, casting, location, scouting, etc.) of show
No. 2, while 8 days simultaneously shooting show no. 1 (single
camera, film) on location.
3.
28 days post-production to airing.
(6.5-8 weeks total)
B. Traditional Sitcom Schedule (excludes weekends)
1.
5-6 days writing a 30 minute show.
2.
1 day read through with actors
3.
2 days blocking with actors
4.
1 day dress rehearsal (shot - multi-camera, video)
5.
1 day live studio audience shoot (multi-camera, video)
6.
28 day post-production to airing
(6 weeks total)
Engendering an aura of anticipation and script control will require an
audience-driven storyline television show (i.e., interactive) to reflect
interactivity sooner than 6 to 8 weeks. To accomplish this requires:
1.
Double-teaming of certain production units (namely, shooting
and editing crews)
2.
Removal of synchronized weekends for the production as a whole
(i.e., each department will operate on it's own 5 day schedule as
dictated by the needs of the show's production).
[0026] It can readily be shown by way of reference to the timeframe examples that a traditional production schedule can be expedited to accommodate audience-enhanced feedback. Below is Table 4, outlining the activities necessary to produce a single episode.
[0000]
TABLE 4
Production Schedule Outline for Episode 5
(4 weeks total, weekends included)
Day 1
Episode 1 airs; Producer approval of Episode 5 Writer
Driven Queries
Day 2
Writer Driven Queries for Episode 5 goes live
Day 3
Writer Driven Queries for Episode 5 close and are tallied
Day 4-8
Episode 5's script is written (5 days)
Day 8
Episode 2 airs; Producer approval of Episode 5's Director
Driven Queries
Day 9
Director Driven Queries for Episode 5 goes live
Day 10
Director Driven Queries for Episode 5 tallied; information
conveyed to Assistant Director to implement during
shoot
Day 7-11
Episode 5's shooting prep (casting, rehearsals, location
scouting, etc.) (5 days)
Days 12-18
Episode 5's shoot, on location (“principal photography”)
(6 days)
Days 14-19
Editing (Assembly to Editor's Cut) (6 days)
Days 15
Episode 3 airs; Producer approval of Episode 5 Editor
Driven Queries
Day 16
Editor Driven Queries for Episode 5 goes live
Day 17
Editor Driven Queries for Episode 5 is tallied
Day 18
Editor Driven scene for Episode 5 is “written” (early AM),
then shot (PM) and delivered to Editor or Editor is directed
to edit in the audience selected ending shot two weeks
earlier
Days 20-24
Producers'/Director's Editing/Cut (5 days)
Day 22
Episode 4 airs; Online Requests are culled from website's
email, chatrooms and bullet boards. “Impromptu” scene
shot to run with either opening or closing credits and
delivered to Editor for insertion in final reel.
Day 24
Picture Lock Episode 5; Website begins coding new
Merchandising
Day 25
Music and Effects mix
Day 26
Additional Dialogue Recording
Days 27-28
Final mixing; Titling (2 days)
Day 28
Producers' viewing (late)
Day 29
Episode 5 airs. On website, new merchandising appears
at airing and emceed Chatrooms open; Webmasters answer,
email live. Simulcast choreography allows changes in
televised storyline to appear in synch with changes on
website. At close of Episode 5, story's archival
information and other story-driven matter (video clips,
music, question tallies, etc.) updated. Chatrooms emcees
and Webmasters remain active after airing.
[0027] The episode production portrayed in the above table is outlined in further detail in Table 5, which includes scheduling overlap for weeks 1-8.
[0000]
TABLE 5
PRE-SEASON
PRE-SEASON
PRE-SEASON
PRE-SEASON
PRE-SEASON
(3 months to Launch 1 )
(5-6 Weeks to Launch)
(3-4 Weeks to Launch)
(2 Weeks to Launch)
STAFF
(June-August)
(Jul 15)
(late August-early September)
(September)
Producers
Approve Road Maps
Approve questions for:
Ep. 2 - Editor Driven Query
(EDQ) 2
Ep. 3 - Director Driven Query”
(DDQ) 3
Ep. 4 - Writer Driving Query
(WDQ) 4
Writers
Storyline Road Map
Audience Queries Road
Map
“Prequel-mercials 5 ” scripts
Episode Aired
“Prequel-mercials 6 ” (Set 1)
“Prequel-mercials 7 ” (Set 2)
Web Team
Website live - platform launch
Questions Appear 8
Questions Closed/Tallied
coinciding with “prequel-mercials”
Ep. 2 - EDQ
Ep. 2 - EDQ
Ep. 3 - DDQ
Ep. 3 - DDQ
Ep. 4 - WDQ
Ep. 4 - WDQ
Prequel-mercials (Set 1)
Prequel-mercials (Sets 1 & 2)
streamed in
streamed in
WEEK 1
STAFF
WEEK 1/DAY 1
DAY 2
DAY 3
DAY 4
DAY 5
DAY 6
DAY 7
Episode
Ep. 1 (Pilot)
Aired 9
Producers 10
Approval of
Ep. 2
Ep. 2 Picture
Ep. 3
Viewing Ep. 2
Questions
Dir/Prod
Lock
Dir/Prod
(late)
Ep. 3 - EDQ
Edit
Review &
Edit Begins
Ep. 3 Dir/Prod
Ep. 4 - DDQ
Review &
comment on
Edit
Ep. 5 - WDQ
comment
Ep. 4 Script
Ep. 2 Dir/Prod
on Ep. 4
Edit
Script
Web Team 11
At time of Ep. 1
Questions
Ep. 3, Ep. 4
Ep. 2
Ongoing Web
airing:
Appear:
and Ep. 5
Coding
Interactive
New
Ep. 3 - EDQ
Monitored
Begins (for
Programming
Merchandising
Ep. 4 - DDQ
Strategy
merchandising,
Contest/games
Emceed chat
Ep. 5 - WDQ
Chatroom
archives,
Fan chatrooms,
rooms open
for Audience
video, music,
video interviews
Active webmasters'
Questions
audio and
with cast
emailing
Closed/Tallied 12 :
text) (after
Ongoing
After Ep. 1 airing:
Ep. 3 - EDQ
Picture Lock)
Portal Services
Update archives
Ep. 4 - DDQ
Character
Continue
Ep. 5 - WDQ
driven links
chatrooms and
Customized pages
email
Opt-in emailed
Update video,
newsletters
music, audio
Email services
and text
Show archives
(clips, episode
summaries, tally
histories, etc.
Writers 13
Ep. 4 Tone
Off
Off
Ep. 4 Prod
Ep. 5 -
Ep. 5 -
Ep. 5
Meeting 14 with
comments
Script/Qs
Script/Qs
Script/Qs
Director
Receive Ep.
Questions to
Ep. 4 Script Lock
5 WDQ tally
Producers
Ep. 5 -
Ep. 4 - EDQ
Script/Qs 15
Ep. 5 - DDQ
Meeting
Ep. 6 - WDQ
with
Webmasters,
re: last
night's
Strategy
Chat vibe
Prep
Ep. 4 Prep
Ep. 4
Ep. 4 Prep
OffOff
Ep. 5
Team 16
Ep. 4 Tone Meeting
PrepEp. 4
Receive and
Prep
with Writer and
Prep
implement
Director
Ep. 4's DDQ
tally.
Shoot
Ep. 3 Shoot 18
Off
Off
Ep. 4 Baton
Ep. 4
Ep. 4
Ep. 4
Team A 17
Pass 19
Shoot
Shoot
Shoot
Shoot
Ep. 3 B roll
Ep. 3
Ep. 3
Ep. 3 Shoot/B
Off
Off
Off
Team B
Ep. 3 Baton
Shoot
Shoot
Roll (whatever
Pass 20
needed)
Editors 21
Ep. 2 Dir/Prod Edit
Ep. 2
Ep. 2 Picture
Receive and
Ep. 3
Ep. 3
Ep. 3
Ep. 3 Edit
Dir/Prod
Lock
edit in Ep.
Editor's
Dir/Prod
Dir/Prod
Edit
Ep. 3 Edit
3's EDQ
Cut 22
Edit Begins
Edit
Ep. 3
tally
Ep. 4 Edit
Edit
Ep. 3 Edit
Begins
Post Team 23
Ep. 2 - Music
Ep. 2 -
Ep. 2
Ep. 2
and Effects
Additional
Final Mix
Final Mix
(M&E)
Dialogue
Ep. 2 Titling
Recording
(ADR)
WEEK 2
STAFF
WEEK 2/DAY 8
DAY 9
DAY 10
DAY 11
DAY 12
DAY 13
DAY 14
Episode
Ep. 2
Aired
Producers
Approval of
Ep. 3
Ep. 3 Picture
Ep. 4
Viewing
Questions
Dir/Prod
Lock
Dir/Prod
Ep. 3 (late)
Ep. 4 - EDQ
Edit
Review &
Edit Begins
Ep. 4
Ep. 5 - DDQ
Review &
comment on
Dir/Prod Edit
Ep. 6 - WDQ
comment on
Ep. 5 Script
Ep. 3 Dir/Prod
Ep. 5 Script
Edit
Web Team
At time of Ep. 2
Questions
Ep. 4, Ep. 5
Ep. 3
Ongoing Web
airing:
Appear:
and Ep. 6
Coding
Interactive
New
Ep. 4 - EDQ
Monitored
Begins (for
Programming
Merchandising
Ep. 5 - DDQ
Strategy
merchandising,
Contest/games
Emceed chat
Ep. 6 - WDQ
Chatroom
archives,
Fan chatrooms,
rooms open
for Audience
video, music,
video interviews
Active webmaster's
Questions
audio and
with cast
emailing
Closed/Tallied:
text) (after
Ongoing
After Ep. 2 airing:
Ep. 4 - EDQ
Picture Lock)
Portal Services
Update archives
Ep. 5 - DDQ
Character
Continue
Ep. 6 - WDQ
driven links
chatrooms and
Customized pages
email
Opt-in emailed
Update video,
newsletters
music, audio
Email services
and text
Show archives
(clips, episode
summaries, tally
histories, etc.
Writers
Ep. 5 Tone
Off
Off
Ep. 5 Prod
Ep. 6 -
Ep. 6 -
Ep. 6
Meeting with
comments
Script/Qs
Script/Qs
Script/Qs
Director
Receive Ep. 6
Questions to
Ep. 5 Script
WDQ tally
Producers
Lock
Ep. 6 -
Ep. 5 - EDQ
Script/Qs
Ep. 6 - DDQ
Meeting with
Ep. 7 - WDQ
Webmasters,
re: last night's
Strategy Chat
vibe
Prep
Ep. 5 Prep
Ep. 5 Prep
Ep. 5 Prep
Ep. 5 Prep
Off
Off
Ep. 6
Team
Ep. 5. Tone
Receive and
Prep
meeting with
implement
Writers and
Ep. 5's DDQ
Director
tally.
Shoot
Ep. 4 Shoot
Off
Off
Ep. 5
Ep. 5
Ep. 5
Ep. 5
Team A
Baton Pass
Shoot
Shoot
Shoot
Shoot
Ep. 4 B roll
Ep. 4 Shoot
Ep. 4 Shoot
Ep. 4 Shoot/B
Off
Off
Off
Team B
Ep. 4 Baton
Roll (whatever
Pass
needed)
Editors
Ep. 3
Ep. 3
Ep. 3 Picture
Receive and
Ep. 4
Ep. 4
Ep. 4
Dir/Prod Edit
Dir/Prod Edit
Lock
edit in Ep. 4's
Editor's
Dir/Prod
Dir/Prod Edit
Ep. 4 Edit
Ep. 4 Edit
Ep. 4 Edit
EDQ tally
Cut
Edit Begins
Ep. 5 Edit
Ep. 4 Edit
Begins
Post Team
Ep. 3 - Music
Ep. 3 -
Ep. 3
Ep. 3
and Effects
Additional
Final Mix
Final Mix
(M&E)
Dialogue
Ep. 3 Titling
Recording
(ADR)
WEEK 3
STAFF
WEEK 3/DAY 15
DAY 16
DAY 17
DAY 18
DAY 19
DAY 20
DAY 21
Episode
Ep. 4
Aired
Producers
Approval of
Ep. 4
Ep. 4 Picture
Ep. 5
Viewing
Questions
Dir/Prod
Lock
Dir/Prod
Ep. 4 (late)
Ep. 5 - EDQ
Edit
Review &
Edit Begins
Ep. 5
Ep. 6 - DDQ
Review &
comment on
Dir/Prod Edit
Ep. 7 - WDQ
comment on
Ep. 6 Script
Ep. 4 Dir/Prod
Ep. 6 Script
Edit
Web Team
At time of Ep. 4
Questions
Ep. 5, Ep. 6 and
Ep. 4
Ongoing Web
airing:
Appear:
Ep. 7 Monitored
Coding
Interactive
New
Ep. 5 - EDQ
Strategy
Begins (for
Programming
Merchandising
Ep. 6 - DDQ
Chatroom for
merchandising,
Contest/games
Emceed chat
Ep. 7 - WDQ
Audience
archives,
Fan chatrooms,
rooms open
Questions
video, music,
video interviews
Active webmaster's
Closed/Tallied:
audio and
with cast
emailing
Ep. 5 - EDQ
text) (after
Ongoing
After Ep. 4 airing:
Ep. 6 - DDQ
Picture Lock)
Portal Services
Update archives
Ep. 7 - WDQ
Character
Continue
driven links
chatrooms and
Customized pages
email
Opt-in emailed
Update video,
newsletters
music, audio
Email services
and text
Show archives
(clips, episode
summaries, tally
histories, etc.
Writers
Ep. 6 Tone
Off
Off
Ep. 6 Prod
Ep. 7 -
Ep. 7 -
Ep. 7
Meeting with
comments
Script/Qs
Script/Qs
Script/Qs
Director
Receive Ep. 7
Questions to
Ep. 6 Script
WDQ tally
Producers
Lock
Ep. 7 -
Ep. 6 - EDQ
Script/Qs
Ep. 7 - DDQ
Meeting with
Ep. 8 - WDQ
Webmasters,
re: last night's
Strategy Chat
vibe
Prep
Ep. 6 Prep
Ep. 6 Prep
Ep. 6 Prep
Ep. 6 Prep
Off
Off
Ep. 7
Team
Ep. 6, Tone
Receive and
Prep
meeting with
implement
Writers and
Ep. 6's DDQ
Director
tally.
Shoot
Ep. 5 Shoot
Off
Off
Ep. 6
Ep. 6
Ep. 6
Ep. 6
Team A
Baton Pass
Shoot
Shoot
Shoot
Shoot
Ep. 5 B roll
Ep. 5 Shoot
Ep. 5 Shoot
Ep. 5 Shoot/B
Off
Off
Off
Team B
Ep. 5 Baton
Roll (whatever
Pass
needed)
Editors
Ep. 4
Ep. 4
Ep. 4 Picture
Receive and
Ep. 5
Ep. 5
Ep. 5
Dir/Prod Edit
Dir/Prod Edit
Lock
edit in Ep. 5's
Editor's
Dir/Prod
Dir/Prod Edit
Ep. 5 Edit
Ep. 5 Edit
Ep. 5 Edit
EDQ tally
Cut
Edit Begins
Ep. 6 Edit
Ep. 5 Edit
Begins
Post Team
Ep. 4 - Music
Ep. 4 -
Ep. 4
Ep. 4
and Effects
Additional
Final Mix
Final Mix
(M&E)
Dialogue
Ep. 4 Titling
Recording
(ADR)
WEEK 4
STAFF
WEEK 4/DAY 22
DAY 23
DAY 24
DAY 25
DAY 26
DAY 27
DAY 28
Episode
Ep. 4
Aired
Producers
Approval of
Ep. 5
Ep. 5 Picture
Ep. 6
Viewing
Questions
Dir/Prod
Lock
Dir/Prod
Ep. 5 (late)
Ep. 6 - EDQ
Edit
Review &
Edit Begins
Ep. 6
Ep. 7 - DDQ
Review &
comment on
Dir/Prod Edit
Ep. 8 - WDQ
comment on
Ep. 7 Script
Ep. 5 Dir/Prod
Ep. 7 Script
Edit
Web Team
At time of Ep. 4
Questions
Ep. 6, Ep. 7
Ep. 5
Ongoing Web
airing:
Appear:
and Ep. 8
Coding
Interactive
New
Ep. 6 - EDQ
Monitored
Begins (for
Programming
Merchandising
Ep. 7 - DDQ
Strategy
merchandising,
Contest/games
Emceed chat
Ep. 8 - WDQ
Chatroom for
archives,
Fan chatrooms,
rooms open
Audience
video, music,
video interviews
Active webmaster's
Questions
audio and
with cast
emailing
Closed/Tallied:
text) (after
Ongoing
After Ep. 4 airing:
Ep. 6 - EDQ
Picture Lock)
Portal Services
Update archives
Ep. 7 - DDQ
Character
Continue
Ep. 8 - WDQ
driven links
chatrooms and
Customized pages
email
Opt-in emailed
Update video,
newsletters
music, audio
Email services
and text
Show archives
(clips, episode
summaries, tally
histories, etc.
Writers
Ep. 7 Tone
Off
Off
Ep. 7 Prod
Ep. 8 -
Ep. 8 -
Ep. 8
Meeting with
comments
Script/Qs
Script/Qs
Script/Qs
Director
Receive Ep. 8
Questions to
Ep. 7 Script
WDQ tally
Producers
Lock
Ep. 8 -
Ep. 7 - EDQ
Script/Qs
Ep. 8 - DDQ
Meeting with
Ep. 9 - WDQ
Webmasters,
re: last night's
Strategy Chat
vibe
Prep
Ep. 7 Prep
Ep. 7 Prep
Ep. 7 Prep
Ep. 7 Prep
Off
Off
Ep. 8
Team
Ep. 7. Tone
Receive and
Prep
meeting with
implement
Writers and
Ep. 7's DDQ
Director
tally.
Shoot
Ep. 6 Shoot
Off
Off
Ep. 7
Ep. 7
Ep. 7
Ep. 7
Team A
Baton Pass
Shoot
Shoot
Shoot
Shoot
Ep. 6 B roll
Ep. 6 Shoot
Ep. 6 Shoot
Ep. 6 Shoot/B
Off
Off
Off
Team B
Ep. 6 Baton
Roll (whatever
Pass
needed)
Editors
Ep. 5
Ep. 5
Ep. 5 Picture
Receive and
Ep. 6
Ep. 6
Ep. 6
Dir/Prod Edit
Dir/Prod Edit
Lock
edit in Ep. 6's
Editor's
Dir/Prod
Dir/Prod Edit
Ep. 6 Edit
Ep. 6 Edit
Ep. 6 Edit
EDQ tally
Cut
Edit Begins
Ep. 7 Edit
Ep. 6 Edit
Begins
Post Team
Ep. 5 - Music
Ep. 5 -
Ep. 5
Ep. 5
and Effects
Additional
Final Mix
Final Mix
(M&E)
Dialogue
Ep. 5 Titling
Recording
(ADR)
NOTE:
EPISODE 5 AIRS ON DAY 29 OF WEEK 5.
1 For purposes of this chart, “Launch Date” is late September.
2 An EDQ or Editor Driven Query (a.k.a. “Drop-In Scene” or “DIS” query) will result in a very short scene that can be shot either: (a) last minute, in less than a half a day by Cameral B Crew, right before Editor's Cut, or (b) shot twice with different endings during Principal Photography. Under the preferred Scenario (b), the change is solely “Editor Driven.”
3 A DDQ or Director Query (a.k.a. “Flavor Query” or “FQ”) will effect the tenor of a subplot storyline. It is written so that accommodating the resulting tally is “Director-Driven” (i.e., can be addressed in Preparation for Principal Photography).
4 A WDQ or Writer Driven Query (a.k.a. “Story Driving Query” or “SDQ”) will effect more pivotal plot changes in storyline, being the basis of an Episode's storyline. Implementing SDQ answers is a “Writer-Driven” task.
5 As part of launch marketing, and to facilitate interactivity earlier in the season, “Prequel-mercials” (story-driven commercials (product driven 30-60 second films)) will be used both for marketing the show and engaging audience participation prior to airing. Prequel-mericials will air 4-6 weeks before TV launch date. Website will begin its platform launch with airing of Prequel-mercials. Questions for TV Episode 2 will appear 3 weeks before airing Episode 1 (not interactive if pilot (previously shot in Spring) is used in this slot).
6 First set of Prequel-mercials is setting up primarily Ep. 2's DIS and Ep. 3's FQ, relegating only one question to Ep. 4's SDQ (Why? Because prequel-mercial format may not be sufficient to gamer a sophisticated SDQ response from an unseasoned audience).
7 Second set of Prequel-mercials is focused on Ep. 3's DIS, Ep. 4's FQ and Ep. 5's SDQ. This second set will air up to Launch (approximately 2 weeks).
8 After written by Writers and approved by Producers, Questions appear on Website (character portals), on toll-free (e.g., 800, 888 or 887) number and are sent to requesting audience participants by email or fax. Answers may be received by Show via Website, return email, fax (scanned) or 800 number. Optional: if limiting audience participation to one character, a registration and password program will have to be implemented and “blocking software” prohibiting repeat online voting. Story questions may go live 3 AM EDT after Show's airing (to accommodate network affiliates' concerns about losing viewer traffic) and are tallied 45 to 48 hours later.
9 At TV airtime, new Merchandising (character/story driven online buying opportunities) associated with that Episode go live on the website. Chatrooms Emcees and Webmasters are live for online commentary/response.
10 “Producers” include Company and Network Producers. When appropriate other senior staff members, e.g., Directors, may be included.
11 “Web Update” occurs right after the TV show closes and consists of updating archives, continuing monitored Chat Room and Email commentary, adding recent show synopsis and other story/audience-driven updating (text, video and music). “Web Update Team” (for both TV Airtime and post-Airtime activity) consists of primarily 1-IMTL Programmers, Content Editors, Web Producers, Designers, etc.
12 Closing either 45 hours (i.e., midnight EDT) or 48 hours (i.e., 3 AM EDT, Day 4), which ever is more viewer-friendly. Only time constraint is to have computer tally completed by time crew/staff arrive in morning on Day 4. Tallied answers are delivered to the following departments for implementation: DIS tally to Editor, FQ tally to Director and SDQ to Writers.
13 Writer(s) will be assigned to each Episode, and will write his/her Episode's Drop-In Scene and Flavor Query scenes, questions, potential outcomes and Editor/Director instructions. The larger unwritten SDQ story (in this case, Episode 5), will be based on advertiser/network approved Story Roadmaps (written during summer before Airing) and Audience Answers.
14 In a “tone meeting” the Writer (and/or Executive Producer) conveys to the Director his/her intentions in the script and the Director expresses any production concerns.
15 Also writing Ep. 5's future DIS and FQ questions, with alternate endings for DIS and crew instructions for Editor and Director, respectively. Ep. 6's SDQ is being written at this time too.
16 “Prep Team” consists of primarily Director, Assistant Directors, Location Managers, Casting Directors, Production Managers, Propmasters, Costumers, Set Designers and all others responsible for facilitating Rehearsals, Casting, Location Scouting and Shoot Scheduling, etc.
17 “Shooting Team” is responsible for Principal Photography consists of primarily those listed above and Camera, Sound, Lighting crews, etc. Note: To best accommodate union rules and human needs, the Prep Team and Shooting Team will consist of separate staff (except Director, who will follow his/her respective episode from start to finish), although the job descriptions are the same.
18 For this chart, “Shoot” means Principal Photography.
19 “Baton Pass” (informational exchange) between Prep Team and Shoot Team A. Director off. Handled by First AD.
20 Baton pass between Shoot Team's A & B.
21 Just like Writers and Directors, Editors will be assigned to follow from beginning to end, the major portions of an Episode (i.e., on Editor will be responsible for bringing the edit through the Editor's Cut, and another for Picture Lock).
22 Editor's version of show is complete and ready for Director/Producer's review and comment.
23 “Post Team” consists of primarily Film Editors, Sound Editors, Music Composers, Soundtrack, Mixers and others responsible for facilitating Post-Production, (i.e., Picture Editing, Sound Editing, Music & Effects (M&E) mixing, Additional Dialogue Recording (ADR), Telecine transfer (film to tape transfer) and Titling, etc.). This chart assumes the Show will be shot on video, and therefore does not account for a Telecine transfer.
The Audience Voice
[0028] Currently, audience feedback can not be directly obtained. Separate advertiser survey companies or rating agencies typically produce reports (e.g., Nielson reports) that are used to monitor audience acceptance of a show. Such reports suffer from an inherent time delay, the fact that they are developed by third-parties and depend heavily on time-consuming diaries and integrity of viewer pool. Although such reports are insightful, they offer lesser value to the individuals engaged in writing, editing, producing and directing a television series (collectively the “production staff”) or other broadcast that must air new material within relatively short intervals.
[0029] The method presented by the invention provides a novel solution to a critical deficiency in the current system. First, the invention allows the production staff to bypass the third-party rating agency and obtain viewer feedback. See FIG. 2 b.
[0030] Second, the invention allows the production staff to obtain viewer feedback immediately after—and, for some purposes, during—show broadcast. Third, the production staff can purposely leave unplanned. certain future story events and, instead, write questions whose responses will provide direction for such events.
[0031] For purposes of story development, audience feedback is filtered predominantly by method of whether the question responded to is an EDQ, DDQ, WDQ or OR. It is anticipated that one or more character webmaster(s) ( 22 ) will be assigned the task of gathering the feedback and communicating with the writers ( 21 ), editors ( 23 a ), directors ( 22 ) and producers ( 24 ), thereby serving as an enabler of audience choice.
[0032] For purposes of advertiser interest/economics, audience feedback gathered from the website/portals and other real-time data is of premium value. While, as described above, such immediate feedback is valuable for determination of preferred character traits, for determination of preferred storyline development and for creation of a more dynamic means of storytelling; such immediate feedback can better enable marketers to market their product by having immediately available information on audience preferences, show/character popularity, audience buying habits, and, or course, audience web-browsing habits. The method of this invention provides a planned means for advertisers to almost simultaneously garner feedback from a significant number of the actual audience members. Such valuable data was formerly only available by conducting focus groups, an expensive and less accurate exercise. To obtain such feedback from a significant percentage of the audience, advertisers and show producers had to wait for third party reports, which, due to presence of the third party polling agency, can be inherently inaccurate and only indirectly satisfy the unique demands of both the advertisers of the show developers.
[0000] The most immediate manner in which audience feedback data can be obtained using the method of the present invention is by real-time monitoring of the character portals ( 14 ), over which the advertisers and show producers can exercise direct control.
Economic Activities and Advertising Advantages:
[0033] In the preferred embodiment, each main character will have his/her own portal ( 14 ), where their weekly audience questions will reside. On each character portal ( 14 ), online merchandising of the character's possessions (clothing, furniture, etc.) can be purchased. Character-driven banner and hyperlink advertisements will also reside on each portal ( 14 ). Chatrooms and fan email (designated character webmaster) allow for interactivity to continue when the show is not on air. Archives (text, video and audio/music) are available for audience member research and entertainment. The e-commerce rich portals will facilitate the collecting of detailed customer intelligence, therefore enabling targeted marketing by advertisers ( 15 ), if so desired. Several advertising and e-commerce vehicles crossing hardcopy, television and internet platforms, including:
Advertising sales (“prequel-mercials,” “webmercials,” other online advertising and print advertising in newsletter) Online merchandising commissions (third-party sales) and retail sales of TV show characters' clothing, make-up, props found on TV set (furnishings, appliances etc.) and soundtrack music (MP3), etc., with parallel offline catalog Licensed merchandise sales (online and catalog) Affinity programs with online and offline retailers Banner ads, buttons and links/affiliate programs Traffic data aggregation and analysis Opt-in email and other offline direct marketing campaigns Fan club membership, subscription newsletters (on and offline) and other premium fan portal services. As an incentive for fan club membership, fans may be granted weighted voting rights.
The “Prequel-Mercial”—
[0042] In order to simulate interactivity early in the TV season with an educated audience ( 10 ), a convergence of advertising, storytelling and interactivity can occur, namely by way of the “prequel-mercial.” Prequel-mercials are story driven commercials of 30-60 second duration that sell product and entice viewership. As part of launch, “prequel-mercials” can be used both for marketing the show and engaging future audience participation. Although primarily a story content vehicle, the expense of prequel-mercials can be subsidized by consumer item product placement. Also, this format can be used throughout the season for strategic storytelling and as a general advertising vehicle for show sponsors.
[0043] Distinct Regional Subplots/Spin-Offs—
[0044] Further anticipated by the invention is the creation of distinct regional subplots, spun-off from the main show. Such stand alone regional sub-stories will “air” online, via streaming media video, and will have story lines that are uniquely generated and modified by regional viewers and supported by local advertising.
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A computer controlled system and method for creating an interactive television show incorporates audience feedback gathered by way of Internet software. Selected inputs include e-mail, as well as telephone and telecopy with these inputs influencing various levels of the script of upcoming episodes. The system provides for enhanced entry of comments and feedback, gathered by way of a calculated overlapping of questions, to allow structured incorporation of such feedback into the complex process for producing weekly and other episodic television shows. This invention further includes means for optimizing advertising revenues through Internet data gathering and dynamic feedback by character webmasters.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of topical glaucoma therapy. More particularly, this invention relates to certain fatty acid salts of 1-{4-[2-(cyclopropylmethoxy)-ethyl]-phenoxy}-3-isopropylamino-propan-2-ol, which is also known as betaxolol. This compound is a known antiglaucoma agent. The use of this compound to treat glaucoma is described in U.S. Pat. No. 4,342,783; the entire contents of this patent are hereby incorporated in the present specification by reference. The structural formula of this compound and its method of preparation are described in U.S. Pat. No. 4,252,984, the entire contents of which are incorporated herein by reference. The hydrochloride salt of this compound is the active ingredient in BETOPTIC®, a topical ophthalmic preparation currently used in the treatment of glaucoma.
Betaxolol is a cardioselective, beta-adrenergic blocking agent. The cardioselectivity of this compound is a significant advantage in the treatment of glaucoma, because the incidence of pulmonary side effects with this compound is significantly less than with other known beta-blockers used in the topical treatment of glaucoma.
The present invention is directed toward improving two aspects of the topical ophthalmic use of betaxolol. First, the duration of action of the hydrochloride salt of betaxolol is approximately 12 hours, which means that a glaucoma patient must administer drops of an ophthalmic solution containing this form of betaxolol two or more times per day to the affected eye(s). The duration of action of betaxolol hydrochloride is believed to be directly related to the high aqueous solubility of this compound, which results in relatively rapid removal of the compound from the eye via the normal bathing of the eye by tears. It is therefore desired to provide a different form (i.e., salt) of betaxolol which is not as prone to this "wash out" effect, and as a result has a longer duration of action than betaxolol hydrochloride.
A second aspect of the current glaucoma therapy with betaxolol hydrochloride which the present invention is directed toward improving is the elimination of a stinging sensation experienced by some patients upon topical application of this form of betaxolol to the eye. This stinging sensation, although experienced in a minority of the patients treated, may interfere with a patient's compliance with prescribed therapy. The provision of a different form of betaxolol which has a therapeutic effect substantially equivalent to or better than that of betaxolol hydrochloride, but which does not cause a stinging sensation upon topical application to the eye, is therefore desired.
SUMMARY OF THE INVENTION
A principal objective of the present invention is the provision of a form of betaxolol which has a longer duration of action than betaxolol hydrochloride upon topical application to the eye.
Another objective of the present invention is the provision of a form of betaxolol which does not cause a stinging sensation when applied topically to the eye or result in any other form of ocular discomfort.
The foregoing objectives and other general objectives of the present invention are achieved by the provision of fatty acid salts of betaxolol. The aqueous solubility of these salts is significantly less than that of betaxolol hydrochloride. This relatively poor aqueous solubility enables these salts to be slowly released from a suitable vehicle when applied topically to the eye. The net effect of this reduced aqueous solubility is a significantly longer duration of action than betaxolol hydrochloride. The present salts of betaxolol are also much less likely to cause ocular discomfort when applied topically to the eye than betaxolol hydrochloride. The present salts of betaxolol and ophtalmic pharmaceutical compositions containing these salts are therefore believed to provide significant improvements in topical, ophthalmic betaxolol therapy.
DESCRIPTION OF PREFERRED EMBODIMENTS
The compounds of the present invention are represented by the formula: ##STR1## wherein n is a whole number of 10 or greater. These compounds may be described as being fatty acid salts of betaxolol. Compounds wherein n is 10, 14, 16, or 18 are particularly preferred. It has been found that n must be 12 or greater in order to reduce the aqueous solubility of betaxolol significantly.
The compounds of formula (I) may be prepared by reacting betaxolol base with a fatty acid of formula:
CH.sub.3 (CH.sub.2).sub.n COOH (II)
wherein n is a whole number of 10 or greater; the preparation of betaxolol base is described in U.S. Pat. No. 4,252,984, the contents of which have been incorporated herein by reference. This reaction may be performed by separately dissolving equimolar amounts of betaxolol base and a fatty acid of formula (II) in ether. The ethereal solutions formed by this initial step are then combined to form a single solution, and this solution is placed in a freezer at a temperature of -10° C. for 16 hours. A suspension of betaxolol fatty acid salt in ether is formed as the result of this step. This salt suspension is next removed from the freezer and allowed to warm to room temperature. The salt is then recovered by means of filtration, washed with ether and dried in vacuuo at 40° C.
The compounds of formula (I) may also be prepared by refluxing a solution containing a fatty acid of formula (II) with an equimolar amount of sodium hydroxide. The resulting solution is then cooled to room temperature and the sodium salt of the fatty acid is collected by filtration and dried at 50° C. Equimolar amounts of the fatty acid sodium salt and betaxolol hydrochloride, which is also drscribed in U.S. Pat. No. 4,252,984, are then dissolved in water and heated to 100° C. The salt which precipitates upon cooling to 0° C. is collected by filtration and dried in vacuuo at 50° C.
The above-described fatty acid salts of betaxolol are contained in the topical, ophthalmic compositions of the present invention in an amount of from about 0.25% to about 10% by weight. The concentrations utilized in these compositions will generally be higher than the concentrations of betaxolol hydrochloride or betaxolol base in analogous compositions because of the relatively poor aqueous solubility of the present compounds. As explained above, this limited solubility provides these compounds with an extended duration of action due to their delayed release from a suitable, pharmaceutically acceptable ophthalmic vehicle when placed in the aqueous environment of the human eye. The duration of action will vary depending on the particular salt employed and the type of ophthalmic vehicle utilized. A duration of action of 24 hours or more is preferred. Accordingly, a typical dosage regimen with the compositions of the present invention will comprise administering a therapeutically effective amount of an ophthalmic composition containing a compound of formula (I) topically to the affected eye once daily (i.e., once per 24 hours).
Because of the low aqueous solubility of the compounds of formula (I), the initial concentration of drug in the precorneal region of the eye will be very low compared to the initial concentration seen when a solution containing an equivalent amount of drug is placed in the eye. In order for a therapeutically useful amount of drug to be present in the precorneal region and ultimately in the aqueous humor, it is necessary that the compounds of formula (I) be delivered to the eye in an ophthalmic vehicle which is retained in the eye for a prolonged period. This retention may be achieved by utilizing a formulation which is retained in the eye either as the result of physical resistance to expulsion by tears, blinking or other natural actions of the eye, or as the result of an affinity of the formulation for ocular tissue. In addition to this retention requirement, the formulation must be aqueous or at least include a continuous aqueous phase in order to facilitate diffusion of dissolved drug and dissolution of undissolved drug.
With the foregoing requirements in mind, a number of suitable types of formulations will be apparent to those skilled in the art of ophthalmic drug delivery. Ophthalmic gels represent a preferred type of formulation, with polymeric gels being partucularly preferred. The polymers which may be utilized to form such gels include all polymers which: (1) are capable of demonstrating batch to batch uniformity; (2) do not demonstrate immunogenicity or other forms of toxicity; (3) are easily sterilized; and (4) are capable of producing a gel having adequate viscosity to facilitate retention of the gel in the eye. Carboxyvinyl polymers represent one example of polymers which are suitable for use in forming ophthalmic gels. Such gels are described In U.S. Pat. No. 4,271,143, the entire contents of which are hereby incorporated by reference in the present specification. Reference is made to this patent for further teaching regarding the use of polymers to form ophthalmic gels.
In addition to the above-described gel formulations, the compounds of formula (I) may also be delivered to the eye by means of oil in water emulsions or microemulsions, liposomes, lipopolysacchasomes, viscous suspensions, polysaccharides, bioretentive beads or bioadhesive polymers.
The compositions of the present invention may optionally comprise one or more ancillary ingredients, such as preservatives (e.g., benzalkonium chloride and thimerosal), surfactants (e.e., polyoxyethylene/polyoxypropylene copolymers and Tyloxapol), tonicity agents (e.g., sodium chloride, potassium chloride, and mannitol) and buffers (e.g., HCl and/or NaOH).
EXAMPLE 1
The following formulation is illustrative of the ophthalmic compositions of the present invention.
______________________________________Ingredient Amount (Wt. %)______________________________________Locust Bean Gum 1.25Xanthan Gum 1.0Betaxolol Eicosanate 1.0Thimerosal 0.01______________________________________
This composition may be prepared by combining all of the ingredients in powder form and then adding purified water or 0.9% sodium chloride solution to form a gel. The combined materials are heated at 75° C. for 30 minutes and then allowed to cool at room temperature.
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Fatty acid salts of betaxolol, a cardioselective beta-blocker, and ophthalmic compositions containing these salts are described. These new salts have an aqueous solubility significantly less than that of betaxolol hydrochloride. This relatively poor aqueous solubility enables the salts to be slowly released from a suitable ophthalmic vehicle when placed in the aqueous environment of the eye. The salts also exhibit a significantly lower incidence of ocular irritation, as compared to ophthalmic solutions containing betaxolol hydrochloride.
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BACKGROUND OF THE INVENTION
The present invention relates to a closure for injecting a material into a hole. More particularly it relates to a tubular one-way closure for injecting synthetic plastic foam material in a drill hole, which closure comprises a throttle channel through which a material is to be injected, a central tube and an elastic tubular sealing member mounted on said central tube.
Closures of this general type have already been proposed. In such a closure an annular internal recess is provided between the central tube and the elastic tubular member, which recess communicates with a through hole in the central tube. The above mentioned internal recess is filled with components of synthetic plastic material, the volume of the thus-filled internal recess is increased and the elastic tubular member is pressed against an inner surface of the drill hole so as to seal the same.
This construction of the closure possesses some disadvantages.
The elastic tubular member serves as the only means for both sealing of the drill hole and anchoring of the closure in the drill hole. In order to perform a sealing action the sealing member must be constituted of a highly elastic material, and therefore such member can not ensure a sufficient anchoring action, which in turn permits undesirable slippage of the closure relative to the inner surface of the drill hole.
It is also possible in this construction that during the filling of the ring-shaped recess only one of the components of the synthetic material enters the recess, with the result that a sufficient expansion of the elastic tubular member can not be obtained. After the injection into a drill hole, the mixing chamber of a pressure pump used for the purpose is cleaned out to remove the synthetic material and prevent hardening of the same in the mixing chamber. For injecting into the next drill hole, the mixing chamber and feeding conduits must be cleaned of said component before dispensing a multicomponent mixture. This moment of time can not be easily fixed which also causes certain difficulties.
Furthermore, pressure produced by foam material and exerted on the elastic member is not sufficient to anchor the closure in a drill hole having a smooth internal surface. This can also result in slippage of the closure relative to the internal surface of the drill hole.
A closure is also known which is glued in the drill hole with synthetic plastic foam material by means of a special operation. This has the disadvantage that an additional loss of time and a separate operation are required. The gluing is carried out in a zone adjacent to a mouth of the drill hole. However, it is desirable to anchor the closure at such a depth that the material to be injected will not be located adjacent an inlet part of the drill hole in the outer area of a longitudinal wall.
The above-mentioned constructions of the closure can be found, for example, in German Pat. Nos. 2,402,509 and 2,205,823.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved tubular one-way closure for injecting a material into a hole, which avoids the aforementioned disadvantages.
More particularly, it is an object of the invention to provide an improved closure which ensures sufficient anchoring of the closure in the drill hole having a smooth internal surface and also sufficient sealing of the drill hole after the anchoring of the closure therein.
Another object of the present invention is to provide an improved closure which can be anchored in and can seal the drill hole easily and quickly without the loss of additional time or the requirement for carrying out an additional operation.
In keeping with these objects, and with others which will become apparent hereafter, the closure for injecting a material into a hole, in accordance with the present invention, briefly stated, comprises a throttle channel through which the material is to be injected; a central tube rotatable about its axis and movable in its axial direction; an expandable anchoring member actuated by the central tube so as to anchor the closure in the hole while being expanded; and an elastic sealing element also actuated by the central tube so as to seal the hole against escape of the material about the closure after anchoring of the same.
The anchoring member comprises an expandable outer shell having an inner conical surface, and an inner actuating member having an outer conical surface slidable over the inner surface of the expandable outer shell. The inner actuating member is threadedly engaged with the outer surface of the central tube so that, during rotating of the latter about its axis, the inner actuating member is moved in the axial direction and expands the expandable outer shell in a radial direction by means of interaction of the conical surfaces, and thereby provides the anchorage of the closure in the hole.
The sealing member has two side surfaces spaced in the axial direction. The central tube has a flange member fixedly connected thereto and adapted while being moved in the axial direction with the central tube to press onto a first of the side surfaces of the sealing member which second surface is supported by an end part of the outer shell of the anchoring member. Thus, the sealing member is compressed in the axial direction and expanded in the radial direction which results in sealing of the hole.
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 a specific embodiment when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE is a partially sectioned side elevational view of a tubular one-way closure in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As clearly shown in the FIGURE, a tubular one-way closure in accordance with the invention comprises a central tube 1 provided with a flange member 10 fixedly connected thereto. In the illustrated embodiment a flange member 10 threadedly engages a threaded part 11 of the central tube 1. A sealing member 4 is provided which is supported by the flange member 10. The sealing element 4 has a tubular part 40 of elastic material, preferably of rubber with a Shore Hardness equal to between 30 and 40 and with textile protective fabric, and two sliding discs 7 and 70 mounted on the central tube with play between the discs and the central tube. The tubular part 40 of the sealing member 4 is located intermediate the discs 7 and 70.
An anchoring member 2 is located adjacent to the sliding disc 70 and comprises an inner expanding cone threadedly engaged with the threaded part 11 of the central tube 1 and an outer expandable shell 21. The inner surface of the expandable shell 21 slidably engages with the outer surface of the expanding cone 20. In the illustrated embodiment the outer shell 21 has an end part 22 embraced by a holding band 23. An equalizing layer 3 of elastic material can be mounted on the outer surface of the expandable shell 21, that is especially desirable when the closure is used in a drill hole 9 made in a broken rock 8. The equalizing layer 3 prevents escape of the injected material through loosened portions of the rock and ensures the anchorage of the anchoring member 2 in a drill hole 9. The equalizing layer 3 is preferably constituted of rubber with a Shore Hardness equal to between 30 and 40.
A tightening element 5 is also provided for tightening the anchoring member 2 against the internal wall 90 of the drill hole 9. In the embodiment shown this element is configurated as a screw nipple 50 threadedly engaged with a threaded part 12 of the central tube 1, which screw nipple also serves as a connecting element for a feeding conduit.
The central tube 1 can be configurated over its entire length as a throttle channel 6. In this case the inner diameter of the central tube is kept so narrow that it permits feeding of a fluid mixture into the drill hole, but prevents discharging of the expanded foam from the same.
The central tube 1 also can be provided with a check valve 13 with a spring element 14, shown in the drawing by the broken lines, which prevents a back flow of the foam. The spring element 14 urges the valve to a closed position. During injection, injected material overcomes stress of the spring element 14 and flows through the open valve 13, whereas thereupon the spring element 14 closes the valve 13 and therefore backflow of the foam is prevented.
The tubular one-way closure, in accordance with the present invention, operates as follows:
After introducing the closure into the drill hole the central tube, by operating of the tightening element 5, is screwed into the inner thread of the expanding cone 20 of the anchoring member 2. The expanding cone is moved in an axial direction and presses onto the expandable shell 21 by means of the interaction of their conical surfaces with one another. Since the expandable shell 21 abuts on the sliding disc 70 of the sealing member 4 and can not move in the axial direction, it expands in a radial direction so as to be pressed against the internal surface of the drill bore. The expandable shell 21 expands easily at the beginning, since it is loosely mounted on the expanding cone 20. The expandable shell 21 does not rotate at the beginning due to its inertia. It also does not rotate later, because then it comes into contact with irregularities of the wall of the drill hole which prevent its rotation. The tubular part 40 of the sealing element is supported by the sliding disc 7, which abuts on the flange member 10, and kept immovable until the expandable shell 21 has become anchored in the drill hole. Expanding of the tubular part 40 of the sealing member starts only after anchoring of the closure in the drill hole. After the expanding of the expandable shell 21 and the anchoring of the same on the wall of the drill hole, rotating of the central tube 1 is continued which results in screwing of the central tube 1 into the expanding cone 20 and movement in the axial direction toward the anchoring member 2. The flange member 10 fixedly connected to the central tube 1 moves together with the same in this direction and presses onto the sliding disc 7 of the sealing element 4. The latter, supported on the other side thereof by the sliding disc 70 abutting on the end part 22 of the anchoring element, is compressed in the axial direction by the flange member 10 and expanded in the radial direction. At the beginning it can be obtained that the expanding of the anchoring element 2 and the expanding of the sealing element 4 are performed alternately, whereby one of the elements serves as a support for the other. The thus expanded sealing element 4 seals the drill hole.
The tubular one-way closure, in accordance with the present invention, provides for highly advantageous results. The construction of the closure ensures the sufficient anchorage of the same in the smooth drill hole and thereafter ensures sufficient sealing of the hole against escape of the injected material about the closure. The closure is anchored in and seals the drill hole easily and quickly without any loss of time or the need for carrying out any additional operations.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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A tubular one-way closure for injecting a material, particularly synthetic plastic foam material, into a hole has a throttle channel through which the material is to be injected, and a central tube rotatable about its axis and movable in its axial direction. The closure also comprises an expandable anchoring member actuated by said central tube so as to anchor said closure in said hole while being expanded, and an elastic sealing member also actuated by said central tube so as to seal said hole after anchoring of the same.
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BACKGROUND OF THE INVENTION
The present invention relates generally to provision of scaffolds for construction purposes and more specifically to motorized scaffold hoisting apparatus for use in general construction work on buildings.
A scaffold is defined as a temporary or movable platform (e.g., a wooden or metal plank) that is supported from below by one or more suitable devices such as a stationary framework or jacks on poles, or suspended from above using rope and tackle or a roof-mounted hoist. Scaffolds are used for supporting workers and also materials of construction such as shingles, bricks, and painting materials. Most scaffolds used for working on two or three story buildings are supported by rope and tackle devices or by jacks on poles. Pole jacks are more convenient to use, but they are more costly. The prior art relating to pole jacks, and poles specially designed for use with pole jacks ("jack poles"), is exemplified by U.S. Pat. Nos. 4,382,488; 4,223,507; 5,042,615; 4,805,735; 4,598,794; 4,597,471; and 5,259,478.
There have been prior efforts to provide motor-powered scaffold hoists for construction work on two and three story buildings, but such efforts have achieved little or no success. Size, cost, adequate fail-safe operation and ease of installation and use are critical factors affecting commercial success.
SUMMARY OF THE INVENTION
The primary object of the invention is to provide new and improved scaffold hoisting mechanisms for use on buildings of limited height, e.g., 2- or 3-story buildings.
Still another object is to provide new and improved electrically-powered scaffold hoisting mechanisms.
A further object is to provide scaffold hoisting mechanisms that incorporate fail-safe brake mechanisms.
A more specific object is to provide novel scaffold-hoisting units that are designed to be slidably mounted on conventional jack poles and are adapted to be driven by conventional portable electric drivers.
Another specific object is to provide scaffold-hoisting apparatus that overcomes deficiencies and limitations of prior devices of like purposes.
A further specific object is to provide apparatus comprising a pole and a scaffold-hoisting device that is mounted on the pole.
These objects, and also other objects rendered obvious by the following description, are achieved by providing novel motorized scaffold hoisting units that are intended to be used in pairs. Each motorized scaffold hoisting unit comprises a carriage that is adapted to be slidably disposed on a jack pole, the carriage comprising a frame section and guide means that restrain the carriage from moving laterally while allowing it to be raised or lowered along the length of the pole. Each hoisting unit also comprises a hoist or winch that is mounted on a platform carried by the carriage and comprises a cable-carrying drum and a power transmission for rotating the drum in response to rotative power supplied by an auxiliary electrically powered driver. The cable carried by the drum has one end affixed to the drum and its opposite end connected to means for attaching it to the upper end of the jack pole on which the unit is mounted. Each carriage also carries at least two fail-safe brake means for releasably gripping the pole on which the carriage is mounted, and scaffold support means in the form of a laterally-projecting arm for supporting a scaffold, e.g., a wooden or aluminum plank. Each power transmission is adapted to be driven by a conventional electrically powered portable driver, e.g., a battery-powered electric drill fitted with a socket wrench that mates with the input shat of the power transmission. Other features and advantages of the invention are disclosed or rendered obvious by the following detailed description of a preferred embodiment and the accompanying drawings.
THE DRAWINGS
FIG. 1 is a side view in elevation of a scaffold-hoisting unit of the present invention in relation to a jack pole on which the unit is to be mounted, the jack pole being shown in phantom solely to better distinguish it from the hoisting unit;
FIG. 2 is a fragmentary front view in elevation of the same hoisting unit;
FIG. 3 is a sectional view in side elevation of the hoisting unit taken along line 3--3 of FIG. 2;
FIG. 4 is a sectional view taken along line 4--4 of FIG. 1; and
FIG. 5 is a fragmentary side elevation on an enlarged scale of the power transmission and its supporting platform, with a portion of a member broken away to show details of a pawl-type transmission lock.
In FIGS. 1-5, like components are identified by like numerals.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-4, the preferred embodiment of the invention comprises a carriage 2 that is designed to make a relatively close sliding fit with a conventional jack pole of rectangular cross-section, e.g., an aluminum pole as shown by U.S. Pat. Nos. 4,223,507; 4,382,488; 4,432,435; 4,446,945; and 5,042,615; or a wooden 2"×4". Carriage 2 has a metal frame of U-shaped cross-section consisting of two parallel side walls 4 and 6 and a connecting front wall 8. Preferably but not necessarily the two side walls have internal right angle flanges 10 at their rear-ends (FIG. 3). Welded to front wall 8 at longitudinally spaced locations are two like channel members 12A, 12B (FIGS. 1, 2 and 3) that define channels for removably accepting workmen guard rails 14. The latter may be conventional wooden 2×4's or extruded aluminum members.
Also bolted to each of the frame side walls 4 and 6 by bolts 15A and 15B and nuts (not shown) are two cantilever workmen scaffold supports that comprise like metal channel members 16A (FIG. 1) that extend forwardly away from carriage 2. Each member 16A has L-shaped flanges 18 along each side edge so as to form guide channels for telescopically receiving complementary channel-like metal extension members 20A. Attached to the forward end of each extension member 20A is a metal bracket 22A having an upstanding leg 24A that functions as a stop. Extensions 20A serve as supports for one end of a plank (a portion of which is shown in phantom at 26) that functions as a platform or scaffold on which a workman can stand. Leg 24A acts as a stop or restraint to prevent the plank from slipping forward off of member extension 20A. The latter can be moved lengthwise relative to channel members 16A toward or away from carriage 2. However, channel members 20A are releasably locked in a selected position relative to channel members 16A by bolts and nuts as represented generally at 23.
A second like pair of cantilever scaffold supports comprising channel members 16B are mounted to side walls 4 and 6 of the frame of carriage 2 above the level of channel members 16A and 20A. Channel members 16B are attached to side walls 4 and 6 by bolts 38A, 38B and 40A, 40B described hereinafter. Channel members 16B extend rearwardly away from carriage 2. Each of the channel members 16B has L-shaped flanges 18B, and channel-like extension members 20B are telescopically coupled to channel members 16B. Channel members 16B and 20B are of like construction as members 16A and 20A respectively. Member 20B carries a bracket 22B identical to bracket 22A. Bracket 22B has an upstanding leg 24B like leg 24A. Channel members 20B are releasably locked to channel members 16B by bolts and nuts as represented generally at 23. This second pair of support arms 16A, 16B acts to support one end of a plank (not shown) that functions as a platform or scaffold for construction materials, e.g., bricks, shingles, etc.
Referring now to FIGS. 3 and 4, two pairs of slide pads 30 and 32 are attached to the inner surface of each of the side walls 4 and 6. Pads 32 are disposed rearward of pads 30. Pads 30 and 32 are made of a low friction material, preferably Teflon ®, and have a thickness such that their inner surfaces will be close to or lightly contact the opposite flat sides 45 (FIG. 1) of a conventional jack pole P of rectangular cross-section, e.g., an aluminum or wood pole as described above. Preferably pole P is constructed in the form of a hollow metal member 39 having a generally rectangular cross-section and a face member 47 that provides a flat face for engagement by confronting components of carriage 2, similar to the aluminum poles described in the patents mentioned hereinabove.
Each pad 30 has a pair of holes that are sized so as to accept cylindrical spacers 36A and 36B (FIG. 3) that are mounted on tie bolts 38A and 38B respectively that are used to secure the two channel members 16B to side walls 4 and 6. The latter walls have holes that are sized to accommodate spacers 36A, B. Channel members 16B have holes sized to accept bolts 38A, 38B but not spacers 36A, 36B. Instead the latter engage the inner surfaces of channel members 16B. Bolts 38A, B are secured in place by nuts. The engagement of the pads 30 with spacers 36A, 36B helps keep those pads in fixed relation to side walls 4 and 6.
Each pad 32 has a pair of holes that are sized to accept cylindrical spacers 40A, 40B that are mounted in a second set of tie bolts 42A, 42B that also serve to secure channel members 16B to side walls 4 and 6. Spacers 40A, 40B and bolts 42A, 42B extend through holes in side walls 4 and 6 (FIG. 4). Channel members 16B have two holes sized to accept bolts 42A, 42B but not spacers 40A, 40B. Nuts 43A, B (FIG. 4) secure bolts 42A, 42B in place. Spacers 40A also serve to rotatably support a stabilizer roller 46 (FIGS. 3, 4) that is sized so that it will engage the adjacent face of pole P. Roller 46 extends between but is spaced a short distance from the two pads 32 so as to be free to rotate on spacer 40A.
Two additional stabilizer rollers 48 (FIGS. 3, 4) are rotatably mounted on another spacer 50 that is mounted on another shaft in the form of a tie bolt 52 that extends through walls 4 and 6 and is secured in place by a nut 53. Bolt 52 also serves as a pivot shaft for a manual brake mechanism hereinafter described. Rollers 48, like rollers 46 and 132, are disposed to engage adjacent surfaces of pole P and thereby limit lateral motion of carriage 2 relative to pole P.
Referring now to FIGS. 1-4, the manual brake mechanism comprises a pair of brake arms in the form of a pair of thin parallel levers 60, 62 that are pivotally mounted on bolt 52. Levers 60, 62 extend outside of side walls 4 and 6 respectively. Spacer 50 (FIG. 3) lightly engages the inner surfaces of lever arms 60, 62 as shown in FIG. 4. The forward (front) ends of brake arms 60, 62 are coupled together by a handle assembly that comprises a tie rod 64 (FIGS. 1 and 3) and a cylindrical handle member 66 that rotatably surrounds the tie rod and extends between the inner surfaces of the two brake arms. The rear ends of brake arms 60, 62 are connected together by a tie rod 68 (FIG. 3) that acts as a pivot shaft for a first brake pad assembly that comprises a pad support 70A and a brake pad 72A. Pad support 70A has a hole 74 that is elongated laterally of its length to accommodate its pivot shaft 68, thereby permitting the pad support to undergo limited lateral motion relative to pivot shaft 68. Side walls 4 and 6 also have holes 76 that are elongated vertically (as viewed in FIG. 3) and also have a width (measured horizontally in FIG. 3) that is oversize relative to shaft 68. Hence, as seen in FIG. 3, brake arms 60, 62 can be rotated on shaft 52 through an arc limited by the size and shape of holes 76.
Pad support 70A is formed with a flat pad-engaging front surface 78 that is provided with ribs 80 that interlock with keyways in pad 72A. The keyways in pad 72A may be sized so as to permit removal and replacement of pad 72 by sliding the latter endwise. Pad support 70A also is formed with a flat back surface 84 that is inclined relative to front surface 78.
The manual brake assembly also includes a cam roller 86 that extends between side walls 4 an 6 and is mounted on a tie rod 88 that extends through and is secured to the side walls in the same manner as bolts 38, 40 and 52. Cam roller 86 is disposed so as to intercept the slanted surface 84 of the pad support when the brake arms 60, 62 are pivoted counterclockwise (as viewed in FIG. 3). When this occurs, cam roller 86 is engaged by pad support 70 and acts on the latter to cause the brake pad assembly to shift forward and also rotate clockwise on pivot shaft 68, thereby forcing brake pad 72 into tight engagement with pole P. It is to be noted that brake arms 60, 62 are urged counterclockwise (as viewed in FIG. 3) by a pair of tension springs 90 which are attached to two stub shafts 92 that are affixed to front wall 8. The other ends of springs 90 are attached to a tie rod 94 that extends between and is secured to brake arms 60, 62. Tie rod 94 extends through holes in side wall 4 and 6 that are oversized so as to allow movement of that tie rod relative to the side walls for the purpose of allowing pivotal movement of brake arms 60, 62. Springs 90 act to keep the brake pad assembly in contact with cam roller 86, so that normally brake pad 72 is engaged with pole P.
Referring now to FIGS. 1-5, the illustrated embodiment of the invention also comprises a hoist or winch support in the form of a platform 98 that has two depending legs 100A and 100B (FIG. 2) that extend down outside of side walls 4 and 6. Legs 100A and 100B are pivotally secured to side walls 4 and 6 by a pivot shaft in the form of a bolt 102 that is secured in place by a nut 104, whereby the platform can pivot relative to carriage 2. Surrounding shaft 102 is a cam roller 105. Extending between and attached to legs 100A, 100B is a travel limit shaft 108 that also extends through two vertically elongated holes 110 (FIGS. 3 and 5) in side walls 4 and 6 of the carriage frame. Secured to travel limit shaft 108 are two connecting levers 114. The bottom ends of levers 114 are pivotally mounted on a pivot shaft 120 that extends between and is carried by forward end portions of two upper brake arms 122A, 122B (FIGS. 1 and 3) that form part of a second fail-safe brake mechanism. The latter are pivotally mounted on a pivot shaft 128 that is mounted to and extends between side walls 4 and 6. A stabilizer roller 132 is rotatably mounted on shaft 128. Roller 132 is sized and positioned so as to engage pole P. The rear ends of upper brake arms 122A, 122B are connected by an upper brake pivot shaft 68B. Rotatably mounted on pivot shaft 68B is a second brake pad assembly that comprises a pad support 70A and a brake pad 72A that are like pad support 70B and brake pad 72. Pad support 70B has an elongated hole 74 to allow lateral movement thereof relative to pivot shaft 136. Side walls 4 and 6 have like holes 76 to permit movement of shaft 68B as brake arms 122A, 122B are pivoted on shaft 128. A pair of tension springs 140 are anchored at one end to a bolt 142 anchored to front wall 8 of the frame 2, while their other ends are attached to rod 120. Springs 140 act to urge brake arms to rotate counterclockwise (as seen in FIG. 3). Cam roller 105 functions like cam roller 86, camming pad support 70B in a direction to force pad 72B into engagement with pole P when arms 120A, 122B are moved counterclockwise as viewed in FIG. 3.
Mounted on and secured to platform 98 is a U-shaped hoist or winch support 99 (FIGS. 1, 2 and 5). A power transmission unit in the form of a gear reducer identified generally by the numeral 150 is attached to support 99. The gear reducer 150 has an input shaft 152 and an output shaft 154. Input shaft 152 is adapted to be connected to the shaft of a separate driver device (not shown). According to the preferred form of this invention, the driver is a separate unit that preferably takes the form of a battery-powered electrical drill or electrical rotating driver (not shown) with a driving tool (not shown) attached to its output shaft that is adapted to mate with input shaft 152. By way of example, shaft 152 may have a hexagonal outer configuration and the driving tool carried by the driver may be in the form of a socket wrench sized and shaped to make a locking connection to shaft 152. Alternatively, shaft 152 may have a hexagonal cavity in its outer end and the driver tool carried by the driver may have a male end sized and shaped to fit in the cavity so as to make a locking engagement with shaft 152.
Referring now to FIGS. 1, 2 and 5, gear reducer output shaft 154 is coaxial with and connected to the shaft 159 of a drum 160. Shaft 159 of drum 160 is rotatably mounted in opposite side walls of U-shaped support 99 (FIG. 2). A flexible metal cable 162 is mounted on drum 160, with one end of the cable being attached to the drum and the other end being secured to a cap member 166 that is adapted to fit on the upper end of a jack pole P. If desired, pole P may have a hole to receive a lock bolt 168 which also extends through opposite walls of cap member 166 and has a nut on its free end, all for the purpose of releasably locking cap member 166 to the jack pole.
Turning now to FIGS. 1, 2 and 5, two cable guides are carried by U-shaped support 99. The cable guides comprise brackets 168 attached to support 99 and pads 170 that are attached to brackets 168 and extend between the two flanges 172 of drum 160. Pads 170 are spaced from drum 160 by a distance that is only slightly greater than the diameter of cable 160 so as to assure that the cable will wrap around the drum in a single layer of turns.
Additionally, the illustrated invention includes a safety lock for the drum and gear reducer. As seen in FIG. 5, the safety lock comprises an angulated link or bracket 180 (FIG. 5) attached to the upper end of carriage 2, and a pawl 182 that is pivotally attached at 184 by the upper end of link 180. Attached to one end of drum 160 is a ratchet gear 186 having a plurality of saw-tooth shaped teeth 188 that are engaged by pawl 182. When engaged, pawl 182 and teeth 188 cooperate to (a) allow the drum to rotate in a direction to permit the drum to rotate so as to cause the cable to wind thereon (counterclockwise as seen in FIG. 3), and (b) prevent the drum from rotating in the opposite direction. However, since link 180 is attached to carriage 2 and platform 99 can pivot relative to carriage 2 on pivot shaft 102, the locking action of pawl 182 on the drum can be disrupted by pivoting the platform 98 clockwise from the position shown in FIG. 5.
MODE OF OPERATION
In practice, erection of a scaffold involves use of two jack poles P and two scaffold-hoisting units made according to this invention, with the carriage of each hoisting unit being mounted on a separate pole in an arrangement (not shown) similar to how two pump jacks are used with two vertical poles for scaffold-supporting purposes (e.g., see prior art patents cited above for pump jack scaffold-supporting arrangements). The free end of the cable 162 of each unit is attached to the top end of the pole P on which the unit is mounted. Then the two poles are erected next to a building wall and an operator-supporting scaffold in the form of at least one plank 26 is positioned so that it extends between and is supported by the laterally-projecting arms 20A of the two units. In this initial setup position, the two hoisting units are located close to the bottom ends of the two poles next to the ground. It should be noted that the pull of gravity will urge the hoisting units in a downward direction, so that the manually operated brake of each hoisting unit is automatically engaged with the poles in a fail-safe mode as a consequence of the action of the associated spring 90, whereby the manually operated brakes operate to prevent the carriages 2 from moving downward. Additionally, unless the cables 162 are under tension, gravity and the pull of springs 140 cause the second brake pads 72B to be automatically engaged with the supporting jack poles
Assuming now that two workmen place themselves on their supporting scaffold (plank 26) carried by the two hoisting units, and further that the two workmen wish to raise their supporting scaffold, they may accomplish this movement by engaging the input shaft 152 of each of the two hoisting units with a suitable tool mounted on the drive shaft of an electrically-powered driver, and then simultaneously activating the two drivers so as to apply rotative power to the power transmissions 150 of the two hoisting units, whereby to cause the two drums to rotate in the direction required to wind the cables on the drums, thereby causing the carriages and hence the workmen supporting scaffold to move up on the two poles. Applying rotative power to the two hoisting units so as to cause those units and the scaffold which they support to move up the two jack poles can be accomplished without manually disengaging the manually operated brake unit, since, unless it is released, that brake (like the brake unit operatively connected to hoist support 98) is designed to impede only downward movement of the hoisting units on the poles.
The two brake units do not lock the hoisting units against upward movement on the poles. In the case of the manually operated brake, on upward movement of the hoisting unit the friction between the brake pads 72A and the poles tends to cause the brake pad supports 70A to move down away from cam rollers 86, thereby effectively freeing those brake pads from the jack poles so as to permit upward movement of the carriages on the poles. On the other hand, unless the manually operated brakes of the two hoisting units are released manually, or unless the hoisting units are urged upwardly by a force exerted through cable 162, the springs 90 of the manually operated brakes and the camming action of cam rollers 86 on the brake pad supports 70 will cause brake pads 72 to be engaged with the two poles, thereby effectively preventing downward movement of the hoisting units on the vertical jack poles.
The second hoist-support coupled brake of each hoisting unit provides a second fail-safe function, since it disengages only when the hoisting cable is under tension and automatically re-engages when tension in the cable is released. In this connection it should be noted that if there is no tension on cable 162, spring 140 will pull hoist-support platform 98 down to the position shown in FIG. 1, in which position brake support member 70B will be engaged with cam roller 104. thereby causing brake support member to pivot so as to bring brake pad 72B into engagement with pole P. As a result, brake pad 72B will lock the carriage against downward movement relative to pole P. However, if drum 160 is urged by the transmission in a direction to wind cable on the drum (whereby to raise the hoisting unit), the tension on the cable will urge platform 98 to pivot in opposition to the force exerted by spring 140. At a certain tension level, the tension on the cable will be enough to overcome the force of spring 140, with the result that the supporting platform 98 is pulled upward (pivoting clockwise as seen in FIG. 3) far enough to cause levers 114 to disengage brake pad support 70B from cam roller 105. When operation of the power transmission in a cable winding direction is deliberately terminated, there tends to be a relaxation of tension on the cable. The extent of the relaxation of cable tension may be sufficient to cause spring 140 to force the upper brake to re-engage pole P, in which cause the hoisting unit is held in place by operation of two brakes. However, if the tension on the cables when the transmissions are stopped is not sufficient to allow re-engagement of the two upper brake mechanisms, the operators may initiate reverse motion of the two transmissions just enough to release the tension on the cables to the extent necessary to re-engage the two upper brake mechanisms.
In the event that it is desired to lower the scaffold, the two operators may accomplish this result by (1) manually disengaging the lower manually-operated brake mechanisms and (2) while those brakes are disengaged, applying power to the two transmissions in a direction to cause them to rotate the drums in a cable-unwinding direction, whereupon the two hoisting units will move down. When the scaffold has been lowered to a desired level, the downward motion of the two hoisting units may be terminated in two ways. The first way is by first terminating operation of the two transmissions and releasing the manually-operated brakes. However, since the cables are still under tension, the upper brake units will still be disengaged from the two jack poles, with the result that the two hoisting units are held in their current elevated position by the now stationary cables. This is not a safe condition, and so it is necessary to reengage the two lower manually operated brake units. This is achieved by releasing the handles 66 of the manual brake units, thereby causing their brake pads 72 to re-engage the two poles. At this point the two hoisting units are now locked against further descent by the engagement of pole P by the two manually operable brakes.
The second way is by first releasing the handles 66 of the manual brake units, thereby causing their brake pads to re-engage the two poles and stopping further downward motion of the two hoisting units. Thereafter, operation of the two transmissions is continued for only a short time sufficient to release the tension on the two cables, in which event the springs 140 cause the two upper brake mechanism to re-engage the two poles P. As a result, two brakes lock each hoisting unit against further descent.
The primary advantage of the upper brake mechanism is that is a fail-safe mechanism. In the event that one or both of the cables should break while the lower brakes are disengaged, the loss of tension in the cable(s) will allow the spring(s) 140 to automatically cause re-engagement of the upper brake mechanism(s), thereby preventing downward movement of the hoisting unit(s).
The transmission lock mechanism constitutes a backup safety measure. In most cases it may be omitted since the inherent nature of a gear reducer is that it is difficult to operate the gear reducer in a backward direction. In essence, the gear reducer acts as a brake when urged in a reverse drive direction. Hence the gear reducer acts to oppose unwinding of the cable on the drum when no input torque is applied to the input shaft of the gear reducer.
Of course the invention may be modified in various ways obvious to persons skilled in the art. Thus, different forms of brake mechanisms may be used. Also the pawl-type lock mechanism may be omitted. A further possible modification is to physically attach reversible electrical motors to the transmissions in place of using separate portable reversible drivers, with those motors being connected by appropriate electrical conductors to a suitable remote power source so as to enable the transmissions to be driven by the motors. Also, it should be appreciated that the term "jack pole" is used merely as a matter of convenience since that term has a certain meaning in the art. Moreover the term "jack pole" is to be deemed to be merely illustrative of various forms of poles that may be used in practicing the present invention, since the form of the supporting pole may be varied in ways obvious to persons skilled in the art. Still other changes will be obvious to persons skilled in the art.
The invention has various advantages. In addition to those advantages mentioned in or rendered obvious by the foregoing description, it should be noted that the hoisting units may be used with various forms of poles. Also the hoisting units are adapted to carry scaffolds not only for supporting workmen but also for supporting constructions materials or tools that are to be used by the workmen. A further advantage is that the transmissions are adapted to be operated by separate portable reversible drivers, and also that the drivers may be electrically powered or pneumatically powered, although electrically-powered drivers are preferred. Also although battery-powered electrical drivers are preferred, the drivers may be of the type that need to be coupled directly to a conventional electrical outlet. Still other advantages will be obvious to persons skilled in the art from the foregoing specification and the accompanying drawings.
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Novel motorized scaffold hoisting units are provided that are intended to be used in pairs with two jack poles. Each unit comprises a carriage that is adapted to be slidably disposed on a jack pole and has guide means that restrain the carriage from moving laterally while allowing it to be raised or lowered along the length of the pole. Each unit also comprises a hoist or winch that is mounted on a platform carried by the carriage and comprises a cable-carrying drum and a power transmission for rotating the drum in response to rotative power supplied by an auxiliary electrically powered driver. The outer end of the cable carried by the drum is adapted to be releasably attached to the upper end of a jack pole on which the unit is mounted. Each carriage also carries at least two fail-safe brake means for releasably gripping the pole on which the carriage is mounted, and means in the form of a laterally-projecting arm for supporting a scaffold, e.g., a wooden or aluminum plank. Each transmission is adapted to be driven by an electrically powered driver, e.g., a battery-powered electric drill fitted with a socket wrench that mates with the input shat of the power transmission.
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FIELD OF THE DISCLOSURE
This disclosure relates to systems for supplying power to one or more electrical loads. More specifically, this invention relates to managing the supply of power to one or more loads in a limited power environment.
BACKGROUND OF THE DISCLOSURE
Transportation systems, such as an aircraft, a ship, or a train, typically provide only a limited supply of power. This power supply serves not only those systems that are essential, but non-essential equipment as well. Aboard an aircraft, for example, the propulsion system provides a finite amount of power to operate both essential equipment, such as life-support, communication, and flight control, and non-essential equipment, such as coffee makers, in-flight commercial phones, in-seat entertainment centers, and a variety of devices operated by passengers.
Because power is limited, non-essential equipment must compete with other non-essential equipment for power. If the load from non-essential equipment exceeds the allowable load, some essential equipment may be deprived of power. Furthermore, the power supply itself may be damaged from the additional loads.
Several systems and methods have been developed to monitor and adjust the power requirements of the load, determining which equipment to turn off and/or causing the equipment to enter a power saving mode (“load-shedding”).
U.S. Pat. Nos. 5,754,445 and 6,046,513, the disclosures of which are incorporated by reference herein in their entirety, describe a power management system in which the load at consumers' outlets (where music players, computing devices, etc. may be plugged in) is continually monitored, and certain not-in-use outlets are disabled when the system enters a power-management mode. A power management circuit is connected to various decentralized power control units (also referred to as power supply units or power converters) each supplying power to one or more outlets. A signal on a line connected to the power control units (hereafter called an ENABLE keyline) indicates whether the system is in an enabled mode or in a power-managed mode. The state of this signal enables or disables outlets that are not in use. In these systems, a consumer device that is in use is not turned off when entering power-management mode.
A system as described in the above-referenced patents is shown schematically in FIG. 1 . Power management circuit 1 monitors the power consumed by the system 3 and compares this level, using a limit comparator 5 , to the power load limit 6 . The ENABLE signal is transmitted to the power control units 2 on ENABLE keyline 7 ; a SET condition signifies that system power is available at the various outlets. When the limit comparator 5 determines that the total power sensed is below the limit, the ENABLE keyline 7 is SET. When a consumer connects a device to an outlet 11 , a request 9 for power is initiated to the control unit. If the ENABLE keyline is SET when the request for power is initiated, the output control 8 enables power to the device plugged into the outlet 11 .
If the limit comparator 5 shows that the power limit has been reached, the ENABLE keyline 7 is reset to signify the additional power is not available. Accordingly, unused power outlets are disabled until the total system power consumption falls below a second threshold (as determined by limit comparator 5 ), at which time those outlets are re-enabled for use by the consumer. Should a consumer have plugged in a device while the system was in the power management mode (so that the device was plugged into a disabled outlet), control latch 10 requires that the user unplug the device and plug it in again to initiate a request for power. In addition, an indicator is typically provided on the outlet to show that power is available. If the indicator is extinguished, the indicator is locked off, so that there will not be an indication that power has been restored until the device is unplugged. This is inconvenient for the consumer, since it is difficult for the consumer to know whether power is available or has been restored in these situations.
Systems have been devised to avoid this consumer inconvenience by automatically connecting power to devices plugged in during a power management phase. In one such system, each power control unit is provided with timers, with a timer connected to each outlet. The timers can impose a delay between activation of the individual outlets in the power control unit. If the ENABLE keyline is SET when a request for power is initiated, the output control enables power to the consumer device plugged into the outlet; no delay is initiated as long as power is available when the device is plugged in. Should the consumer have plugged in the device while the system is in the power management phase (that is, the ENABLE keyline signifies that no additional power is available and unused outlets are disabled), the timer limits when the outlet may be reconnected. The timer starts a delay period during which the limit comparator senses the total power consumption. When the delay period expires, if additional power is still available the outlet is automatically activated. The next outlet in the power control unit is likewise activated with a delay if a device was plugged in during the power management phase; this continues until the final outlet in the unit is activated.
More recently, a system has been disclosed having specifically random timer action for enabling of individual outlets connected to a decentralized power supply unit. This system is shown schematically in FIG. 2 . Power management circuit 42 monitors the power consumed by the system 44 and compares this power level to the power limit 43 using limit comparator 41 . When the limit comparator 41 determines that the total power sensed is below the limit, the ENABLE keyline 33 is SET. As a consumer connects a device to outlet 39 , a request for power 38 is initiated to the power supply unit 45 . If the ENABLE keyline is SET when the request for power is initiated, output control 40 enables power to the device plugged into outlet 39 . No delay is initiated as long as power is available when the device is plugged in.
If the limit comparator 41 determines that the power limit has been reached, the ENABLE keyline 33 is reset to signify the additional power is not available. Unused power outlets 46 , 47 accordingly are disabled until the total system power consumption falls below a second threshold as determined by limit comparator 41 and re-enables outlets 46 , 47 for use by the consumer.
Should a consumer have plugged in while the system is in the power management mode (that is, ENABLE keyline 33 signifies that no additional power is available and unused outlets are disabled), and subsequently the power consumption 44 falls below the threshold determined by limit comparator 41 , then the ENABLE keyline is SET and timers 35 , 36 , 37 determine when each respective outlet will be reconnected. In this system, the timers are initiated at the same time, but cause delays of random lengths at the respective outlets. As each random delay time expires, the associated outlet is enabled if the ENABLE keyline 33 remains SET.
All of the decentralized power supply units 45 , 50 , etc. receive the ENABLE keyline signal at the same time. All of the random timers in each power supply unit thus start at the same time. Since the delays are of random lengths, the risk of two loads being activated simultaneously is reduced. However, in a system where multiple power supply units are attached, a number of outlets with loads still may be activated within close proximity in time. This may not allow enough time for the power management circuit 42 to measure the consumed power and control the ENABLE keyline to limit the number of outlets activated to avoid a system overload.
In the timed automatic-connect system and random-timer system described above, there may be loss of control of the power load during the re-connect sequence so that the system maximum is inadvertently exceeded. For example, laptop computers typically require several seconds before the charging circuit reaches full current. In addition to the device delay time, there is a period of time required for the power management circuit to measure the power consumed, and for the limit comparator to determine if additional power is available and set the ENABLE keyline appropriately. If the system has several power control units, a number of outlets with loads may be activated simultaneously or nearly simultaneously, and thus cause overload of the power system.
The systems described just above avoid inconvenience to the consumer, but allow a potential for loss of system control and overload of the power system. There remains a need for a load management system for limited power environments that can re-connect devices while maintaining control of the overall load.
SUMMARY OF THE DISCLOSURE
In accordance with an aspect of the disclosure, a system for managing distribution of electrical power includes a power management circuit, a plurality of power control units, a first keyline and a second keyline. The power management circuit includes a device configured to measure power consumed by an electrical load, and a comparator configured to compare the measured power with a power limit. Each of the power control units includes at least one outlet for delivering power to a load; a timing control circuit coupled to each outlet and configured to deliver an enabling signal to each outlet individually with a time delay; a signal input; and a signal output. The first keyline connects the power management circuit with the signal input of one of the power control units; the second keyline connects the signal output of that power control unit with the signal input of another power control unit. Each power control unit is configured to propagate a signal to another power control signal via the second keyline.
The keylines deliver either a SET or RESET signal, depending on whether the measured power does not exceed the limit or exceeds the limit, respectively.
In accordance with another aspect of the disclosure, a method for managing distribution of electrical power includes measuring power consumed by an electrical load; comparing the measured power with a power limit; delivering one of a SET signal and a RESET signal to a power control unit, in accordance with the measured power not exceeding the power limit and exceeding the power limit respectively; and propagating one of the SET signal and the RESET signal, in accordance with the signal delivered to the power control unit, to another power control unit. The power control unit includes at least one outlet and a timing control circuit. The SET signal causes the timing control circuit to send an enabling signal to the outlet, thereby making power available at the outlet; the RESET signal prevents the timing control circuit from sending an enabling signal to an outlet not connected to a consumer device at initiation of the reset condition. In specific embodiments, the SET/RESET signal is delivered using a first keyline connecting one power control unit to a power management circuit configured to perform the measuring and comparing steps, and the signal is propagated using a second keyline connecting that power control unit to the other power control unit; the first keyline is separate from the second keyline.
In accordance with another aspect of the disclosure, a method for managing distribution of electrical power by a power system (where the system includes a plurality of power control units each having an outlet coupled thereto and a timing control circuit) includes measuring power consumed by an electrical load; comparing the measured power with a power limit to obtain a first comparison result; and, in accordance with the first comparison result indicating the measured power exceeding the power limit, preventing connection of an additional load to the power system. Subsequently, the measured power is compared with the power limit to obtain a second comparison result. In accordance with the second comparison result indicating that the measured power does not exceed the power limit, an enabling signal is delivered to one power control unit, causing the timing control circuit to send a signal to the outlet and thereby permitting connection of additional loads to the power system. The enabling signal is propagated to another power control unit. In specific embodiments, the enabling signal is delivered using a first keyline connecting the power control unit to a power management circuit, and the enabling signal is propagated using a second keyline, separate from the first keyline, connecting the power control unit to another power control unit.
The foregoing has outlined, rather broadly, the preferred features of the present disclosure so that those skilled in the art may better understand the detailed description of the disclosure that follows. Additional features of the disclosure will be described hereinafter that form the subject of the claims of the disclosure. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present disclosure and that such other structures do not depart from the spirit and scope of the disclosure in its broadest form.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates a load distribution and management system in accordance with a prior disclosure.
FIG. 2 schematically illustrates a load distribution and management system with power supply units having random timers, in accordance with another prior disclosure.
FIG. 3 schematically illustrates an enhanced load management and distribution system in which a signal enabling activation of power outlets is propagated from one power control unit to another, in accordance an embodiment of the present disclosure.
FIG. 4 is a flowchart schematically illustrating operation of an enhanced load management and distribution system in accordance with an embodiment of the disclosure.
FIG. 5 is a flowchart schematically illustrating startup of a system according to an embodiment of the disclosure, in which no user devices are plugged in.
FIG. 6 is a flowchart schematically illustrating startup of a system according to an embodiment of the disclosure, in which user devices are plugged in.
FIGS. 7A and 7B are connected flowcharts schematically illustrating operation of a system according to an embodiment of the disclosure in a power management mode.
DETAILED DESCRIPTION
As described in detail below, embodiments of the disclosure include a power distribution and management system with a strategically controlled re-connect function, including a power measurement device, power controller units, and outlets for delivering power to distributed loads. Operation of the system, in accordance with embodiments of the disclosure, includes systematically connecting loads when power is available, in a controlled manner such that system power consumption can be maintained below a prescribed maximum limit; the system maintains controlled power management without the need for manual intervention.
System Overview
A system according to an embodiment of the disclosure is shown schematically in FIG. 3 . Power management circuit 51 includes a limit comparator 55 which has an input corresponding to the power consumed by the system 53 and another input corresponding to the maximum power limit 54 . The power management circuit distributes system power to a plurality of power control units 52 , 70 , etc. via power keyline 12 . Each power control unit (e.g. power control unit 52 ) is connected to several power outlets 64 , 66 , 68 . Each outlet has a power connection to the power control unit, and a line 65 , 67 , 69 for transmitting a request for power to the power control unit. As shown in FIG. 3 , outlet 64 is associated with an enabling circuit 59 which receives a power request 65 and an enabling signal 60 , and is connected to an outlet control 58 for controlling delivery of system power to the outlet. Each power control unit has a timing control circuit 63 which sends appropriate enabling signals 60 , 61 , 62 to the outlets 64 , 65 , 66 respectively. Timing control circuit 63 is connected to a first ENABLE keyline 56 and a second ENABLE keyline 57 . Timing control circuit 63 receives the status of the ENABLE keyline 56 as an input, and outputs an appropriate signal to the next power control unit 70 over the second ENABLE keyline 57 .
An overview of operation of a system embodying the disclosure is shown in FIG. 4 . The power management circuit monitors the system power consumption (step 401 ) and compares that power level to the power limit (step 402 ). If the power limit has not been reached, the first ENABLE keyline is SET (step 403 ) and this signal is input to a power control unit (step 404 ). The power control unit proceeds to evaluate the status of the outlets in that unit. If there is a request for power at an outlet, the outlet is enabled in accordance with that request (step 405 ) and a time delay begins as described in detail below. During the time delay, the total power consumed continues to be monitored by the limit comparator (step 406 ). If the power limit has not been reached, the status evaluation is repeated for each outlet of the power control unit sequentially (step 407 ). The ENABLE keyline signal SET is then propagated to the next power control unit (step 408 ). These steps are repeated for each power control unit to the last power control unit in the system (step 409 ).
If the total system power limit is reached (step 406 ), the ENABLE keyline is reset (step 410 ). Unused outlets of the power control unit are immediately disabled (step 411 ) and evaluation of outlets where consumers have plugged in devices is immediately halted (step 412 ). The RESET signal is propagated immediately through each of the power control units (step 413 ) to the last power control unit (step 414 ). The system then operates in the power management mode until the power consumption level is sufficiently reduced to permit a transition to the enabled mode. Details of power management operation and the transition sequence are also discussed in detail below.
System Enablement without User Devices Plugged In
FIG. 5 schematically illustrates the procedure of enablement of the system when no user devices are plugged in, in accordance with an embodiment. Power management circuit 51 monitors the power consumed by the system 53 and compares this power level to the maximum power limit 54 , using limit comparator 55 (step 501 ). When the limit comparator 55 determines that the total power sensed has not reached the limit (step 502 ), the ENABLE keyline 56 is SET (step 503 ). This signal is input to power control unit 52 , and timing control circuit 63 accordingly initiates evaluation of the outlet states for outlets 64 , 66 , 68 (step 504 ). Outlet 64 is enabled by signal 60 (step 506 ). The power control unit monitors outlet 64 to determine whether power is being requested by a power request signal 65 (step 507 ); if not, enable signal 61 is activated and the next outlet, outlet 66 , is evaluated via power request signal 67 (step 508 ). This sequence continues until all outlets have been evaluated; the ENABLE signal SET is then propagated on ENABLE keyline 57 (step 509 ), initiating the same sequence in the next power control unit 70 . This procedure continues to the last power control unit in the system.
System Enablement with User Devices Plugged In
FIG. 6 schematically illustrates the procedure of enablement of the system when at least one user device is plugged in, in accordance with an embodiment. Power management circuit 51 monitors the power consumed by the system 53 and compares this power level to the maximum power limit 54 , using limit comparator 55 (step 601 ). When the limit comparator 55 determines that the total power sense has not reached the limit (step 602 ), the ENABLE keyline 56 is SET (step 603 ). This signal is input to power control unit 52 , and timing control circuit 63 accordingly initiates evaluation of the outlet states for outlets 64 , 66 , 68 (step 604 ). Outlet 64 is enabled by signal 60 (step 606 ). The power control unit monitors outlet 64 to determine whether power is being requested by a power request signal 65 (step 607 ); if not, enable signal 61 is activated and the next outlet (in this case outlet 66 ) is evaluated via power request signal 67 (step 608 ). If the outlet being evaluated is the last outlet in the power control unit and the ENABLE keyline is still SET, the ENABLE keyline signal is propagated to the next power control unit (step 609 ).
If power is requested, the request is granted and outlet control 58 causes power to be provided to the outlet (step 610 ). A timer is then initiated (step 611 ) delaying evaluation of the next outlet by a predetermined interval. The delay time is long enough (e.g. 10 seconds) to permit the load at the outlet to reach full power and for the power management circuit 51 to evaluate the total power consumed (step 612 ). The total power consumed continues to be monitored by the limit comparator 55 ; if the power consumed 53 has not reached the maximum power limit (step 613 ), the ENABLE keyline 56 remains SET. When the delay time expires, if the ENABLE keyline 56 is still SET, the next outlet will be evaluated (step 614 ). If a user device is plugged into the next outlet (in this case outlet 66 ) and a request 67 for power is active, the same sequence is performed by the timing control circuit 63 while the power management circuit 51 evaluates the total power consumed. If a user device is not plugged into an outlet (e.g. the next outlet 68 ), the timing control circuit evaluates that outlet without a delay. This sequence is repeated for all of the outlets connected to the power control unit. If the outlet being evaluated is the last outlet in the power control unit and the ENABLE keyline is still SET, the ENABLE keyline signal is propagated to the next power control unit (step 615 ).
This procedure permits evaluation of the loads one at a time, thereby ensuring that the system maximum power load is not exceeded. In particular, the ENABLE keyline signal is propagated from one power control unit to another, as opposed to being transmitted to all power control units at once. This ensures that, during a transition from RESET to SET of the ENABLE keyline, only one outlet is evaluated (with an ample measurement time) and enabled before moving on to evaluate the next outlet.
If the total system power has reached the limit, the ENABLE keyline 56 is reset (step 616 ). This is propagated immediately through each of the power control units 52 , 70 , etc. This ensures that when the system has reached the maximum load limit, the unused outlets are disabled and the evaluation of consumer devices is halted. The system then enters power management mode.
Normal Operation
Normal operation is characterized by the ENABLE keyline signal being SET (that is, enable mode). As a consumer connects a device to outlet 64 , a request for power 65 is initiated to the power control unit 52 . If the ENABLE keyline 56 is SET when the request for power is initiated, outlet control 58 enables power to the outlet and thence to the device. No delays are required, due to the ENABLE keyline being SET prior to the request for power 65 .
Power Management Operation
When the total system power as determined by the power management circuit 51 reaches the limit, the ENABLE keyline 56 is reset (step 616 ). The RESET signal input to a power control unit causes unused outlets to be disabled (step 701 ) and evaluation of outlets to be halted (step 702 ). The ENABLE signal RESET is propagated through each of the power control units 52 , 70 , etc. (step 703 ) to the last control unit (step 704 ).
The power management circuit continues to monitor the system power consumption (step 705 ). As the total power consumed falls below the maximum limit 54 , as determined by limit comparator 55 (step 706 ), the ENABLE keyline 56 is SET (step 707 ). The SET signal is input to power control unit 52 (step, which starts the evaluation of the outlets 64 , 66 , 68 connected to the power control unit (step 752 ). Outlets are enabled and evaluated one by one as described above (step 753 ). Each outlet is evaluated for the presence of a power request (step 754 ). If an outlet is not requesting power, the evaluation sequence proceeds to the next outlet (step 759 ). If an outlet is requesting power that previously had power (that is, the outlet was in use upon entering power management mode) (step 755 ), power to that outlet is maintained (step 756 ) and the sequence proceeds to the next outlet (step 757 ). If the outlet being evaluated is the last outlet in the power control unit and the ENABLE keyline is still SET, the SET signal is propagated to the next power control unit via keyline 57 (steps 758 , 760 ).
For each outlet that is requesting power that did not have power granted prior to the maximum limit being reached, the timing control circuit causes a delay as that outlet is activated (see FIG. 6 , steps 610 - 611 ). When that time delay expires and if additional power is still available (steps 612 - 613 ), the SET signal is propagated to the next power control unit (step 615 ). This signal will continue to propagate through the system until either the maximum power limit has again been reached, or the end of the chain of power control units is reached while the system power consumed remains below the limit.
Alternate Embodiments
In alternate embodiments, the ENABLE keyline 56 , 57 , etc. is not a physical connection from one power control unit to another; a communication bus may be provided to enable power control units one at a time. In still other embodiments, the power management circuit 51 may be a standalone unit integrated into a power management system that is part of an aircraft power distribution system, or be configured as another means of controlling a measuring power.
While the disclosure has been described in terms of specific embodiments, it is evident in view of the foregoing description that numerous alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the disclosure is intended to encompass all such alternatives, modifications and variations which fall within the scope and spirit of the disclosure and the following claims.
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A system for managing distribution of electrical power includes a power management circuit, power control units, a first keyline and a second keyline. The power management circuit includes a device configured to measure power consumed by an electrical load, and a comparator comparing the measured power with a power limit. Each power control unit includes an outlet for delivering power to a load; a timing control circuit coupled to each outlet and configured to deliver an enabling signal to each outlet individually with a time delay; a signal input; and a signal output. The first keyline connects the power management circuit with the signal input of one power control unit; the second keyline connects the signal output of that power control unit with the signal input of another power control unit. Each power control unit is configured to propagate a signal to another power control signal via the second keyline.
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FIELD OF THE INVENTION
The invention is related to the field of optical telecommunications, and in particular, to method for optimizing optical receiver control loops.
BACKGROUND OF THE INVENTION
It is well known that signals transported over an optical network suffer degradation between associated transmitters and receivers. There are many possible causes for the transmitted optical signals to degrade; among them are polarization mode dispersion (PMD), chromatic dispersion (CD), etc. Some of those effects might change the signal characteristic over time, some effects are temperature dependant. No matter what caused the degradation, the more the received signal is distorted, the more errors will be made at detection up to the point where the transmission becomes ineffective.
There are many ways to compensate for errors at the receiver. For example, forward error correction (FEC) is commonly used in optical transmission networks to correct errors of the received signals. In FEC, the transmitted signals include redundant information used for reconstruction of the transmitted sequence (error correction). Another example is an adaptive receiver that allows for the receiver to adjust and/or modify optical and/or electrical components thereby reducing the amount of errors received at the receiver. A combination of the two examples is also possible.
The adaptive receiver functions well in static optical networks where signals travel substantially the same path. Slow changes in the input signal characteristic at the receiver might be compensated by adjustments done by the adaptive receiver. The input signal characteristics can be compensated as long as the time constants of the adaptive receiver are faster than the signal changes. In particular, if some of the adjustments of the adaptive receiver are based upon the number of errors computed from the overhead information, then the time constants of the adaptive receiver are dependant on the signal quality. In that case, some of the adjustments might start to drift from the optimum for high quality input signals. This drift might be caused either by some offset in the control loop and/or by slowly changing characteristics of the input signal to the optical receiver. This will be termed ‘the receiver is outside the active control region’ henceforth.
However, in an optically switched WDM network where the optical signals are constantly being switched onto different paths, the signal characteristic could change abruptly at the receiver. The latter is not limited to the switched signals but also applies to neighbor channels of the WDM link. The sudden change of signal characteristic will most probably result in drastic increase of errors at the receiver if the adaptive receiver is not at the optimum setting. As a result, the FEC might not be able to compensate for the errors at the receiver. If the settings of the adaptive receiver have drifted from the optimum settings, transmission faults will likely occur.
An object of the present invention is, therefore, to enable the adaptive receiver to find and track the optimum setting thus enhancing the robustness against abrupt signal degradation.
SUMMARY
Various deficiencies of the prior art are addressed by the present invention of methods for an optical receiver having a control loop using Bit Error Rate (BER) as a feedback. In one embodiment, the invention provides for a method of determining a bit error rate (BER) associated with a received optical signal and providing indication of said BER to a control loop adapted to adjust the optical signal in a manner tending to reduce the BER. In accordance with the method, the received optical signal is adapted in a manner tending to increase the BER such that the control loop operates within an active control region.
Another embodiment of the invention provides a method for using an alternate feedback signal for an adaptive optical receiver normally based upon the bit error rate (BER). The feedback signal will be called ‘vertical eye opening’ and is based upon a combination of evaluating the BER feedback and actively controlling the optical receiver as described in the first embodiment.
In another embodiment of the invention, a data transmission system wherein data transmitted to a receiver via a network is adapted via a transmitter control mechanism in response to a bit error rate (BER) signal provided by the receiver. The system adjusts, at said transmitter and/or receiver, at least one parameter of a received data signal to cause the BER associated with the received data signal to be within a range of BER values. In accordance with the invention, the range of BER values corresponds to an active control region.
The invention further provides other methods and system elements that implement various aspects, embodiments, and features of the invention, as described in further detail below.
The foregoing, together with other aspects of this invention, will become more apparent when referring to the following specification, claims, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The teachings of the present invention can be readily understood by considering the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 depicts a block diagram of an optical transmission system;
FIG. 2 depicts a block diagram of an optical receiver system according to an embodiment of the invention;
FIG. 3 depicts a flow diagram of a method according to an embodiment of the invention; and
FIG. 4 depicts a graphical representation useful in understanding the present invention.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be primarily described within the context of an optical receiver in an optical switched network; however, those skilled in the art and informed by the teachings herein will realize that the invention is also applicable to any apparatus and method that use control loops in a communications network.
FIG. 1 depicts a block diagram of an optical transmission system. The optical communications network 100 of FIG. 1 includes a transmitter with forward error correction (FEC) encoding 110 , an optical transmission link 120 , and a receiver system 130 . The receiver system includes a receiver with FEC decoding 132 and a controller 134 .
The transmitter 110 may comprise a conventional device, group of devices or any system configured to receive an input data signal D in and provide a corresponding modulated data signal. D in may comprise an electrical input signal or an optical input signal. The output will be an optical signal which could be a wavelength division multiplexed (WDM) signal or other types of optical signals. The transmitter 110 also accepts a feedback control which allows the characteristics of the outputted optical signals, such as the output power, to be selectively varied.
The optical link 120 may include conventional optical fiber or any part of an optical fiber network that transports optical signals. An example of the link could include optical fibers or the like. The optical link 120 could comprise optical components such as optical amplifiers (OA) or polarization mode dispersion (PMD) compensators (not shown). The optical link 120 is the conduit for the optical signals traveling from the transmitter 110 to the receiver 130 . This link also may accept feedback control signals from the receiver 130 which allows for the modification and adjustment of the characteristics of the optical signals being transmitted such as e.g. output power of the OA.
The receiver system 130 includes a receiver with FEC 132 and a controller 134 . The receiver with FEC 132 may include any device, group of devices or system configured to receive and correct the errors of the received optical signals. Error correction will be performed on the received signal and the receiver 132 will output the inputted signals as electrical signals D out . The receiver 132 will monitor the number of received errors. The ratio of the number of error bits to total number of bits received is known as the bit error rate (BER). The BER is transmitted from the receiver 132 to the controller 134 . The BER is used by the controller 134 to determine if adjustments need to be made to certain components of the optical network. Depending on the received BER, the controller 134 will transmit a feedback signal to the transmitter 110 , the link 120 , or the receiver system 130 in order to increase the system margin against degradation in the received optical input signal.
FIG. 2 depicts a block diagram of an optical receiver system 130 according to an embodiment of the invention. The optical receiver system 130 may include the following components: an optical amplifier 210 , a tunable dispersion compensator 220 , an optical to electrical (O/E) converter 230 , a clock and data recovery (CDR) circuit 240 , a data processing circuit 250 and a controller 134 .
The optical receiver system 130 accepts as input the received optical signal which is received by the optical amplifier (OA) 210 which could be an erbium-doped fiber amplifier (EDFA). The OA might be able to adjust the signal power delivered to the dispersion compensator by using a variable optical attenuator (VOA) located in the OA. The VOA may be configured to respond to the feedback power control (PC) signal.
The tunable dispersion compensator 220 is a standard component for compensating for the chromatic dispersion of the input optical signal. Compensator 220 receives an amplified optical signal from the output of the OA. The compensator 220 adjusts the received optical signal to compensate for chromatic dispersion (CD). A chromatic dispersion control (CDC) is used as feedback control for compensating the signal for CD by the tunable dispersion compensator 220 . The compensated optical signal is then outputted from the compensator 220 .
The optical signal then passes to the O/E converter 230 . The O/E converter could be a photodiode or integrated photo receiver. This component receives the optical signal from the tunable dispersion compensator 220 and outputs the electrical equivalent of the received optical signal.
The CDR 240 receives the outputted electrical signal from the O/E converter 230 and outputs the clock signal and the data signal. CDR uses decision threshold and sampling phase information in order to derive the clock and data signals from the received signal. CDR could consist of one or more components. Clock and data recovery control (CDRC) may be received by the CDR as feedback control signal. CDRC could be used to influence the decision threshold and/or sampling phase of the received signal.
The data processing circuit 250 uses the clock and data signals and performs, among other functions, FEC decoding on the received signal to obtain the originally transmitted signal. It also informs the controller 134 of the BER at the optical receiver 132 . Determining BER is well known in the art. For example, some possible methods, alternative to using the information from the FEC overhead, include analyzing the eye diagram, Q-factor or the like.
The feedback control signals mentioned above are generated by the controller 134 and transmitted back to the different components and devices of the system. The system may have some or all of the control loops shown in FIG. 2 . The system might also have additional control loops based on the BER feedback not shown in FIG. 2 . The receiver system 200 may have a clock and data recovery control (CDRC) loop that allows the controller 134 to adjust the decision threshold in the CDR 240 by using the information transmitted in a CDRC feedback signal to the CDR 240 . The controller 134 could also adjust the sampling phase of the received signal at the CDR 134 by transmitting another type of control information in the CDRC. Another possible control loop is the chromatic dispersion control (CDC) loop which allows the controller 134 to tune the dispersion compensator to adjust the receiver to compensate for CD of the optical channel. There could also be a control loop for adjusting the output power of the optical amplifier by transmitting a PC to the optical amplifier. That OA could be located either in the receiver or elsewhere in the optical transmission system. The controller 134 might also form a feedback control loops to the transmitter 110 and/or the transmission link 120 of FIG. 1 . For example, the controller might send a feedback signal to adjust the PMD compensator which might be located in the transmitter 110 or in other parts of the optical link 120 . The controller 134 could also send a feedback signal to the transmitter 110 to adjust the output power of that transmitter 110 or other parameters that influence the characteristics of the optical signal, e.g. MZM bias or duty cycle.
In one embodiment, the BER is used to optimize the components of an optical network by advising the controller to adjust for different parameters of the optical signals. The control loops using the BER information can optimize the parameters of the optical switched network. The controller 134 will receive a BER from the data processing circuit 250 which will allow the controller to know the quality of the received signal. Depending on the value of BER, the controller can selectively send feedback control information to certain components in the system. The control information can vary the parameters of the components and decrease BER that has been received at the receiver 130 .
There are some parameters of the fiber link that can change over time. E.g. the amount of chromatic dispersion for the received optical signal is affected by the temperature of the transmission fiber and thus changes with temperature. If the BER of the transmission network is low, the receiver will not notice the dispersion of the fiber has changed as the receiver will not receive any bit errors. As a result, that control loop could be off the optimum. Thus, receiver will not receive an optimum signal.
In an optical switching network, signal quality may degrade very fast. This is due to the physical nature of the optical network. For example, when a wavelength is added to a WDM signal, all other wavelengths in the signal will be affected. Depending on the system design target, adding an additional wavelength can take between 1 millisecond and 1 second.
Keeping track and maintaining the input signal at optimum even when the BER at the moment is low is important to the present invention. In the case of the switched network, there could be sudden degradation of input signal. The receiver could have very good BER at one moment, then receiving an enormous amount of errors less than one second later. It is practically impossible to keep track of all the settings of all the receiver control loops in such a short time. The FEC might have problems correcting all the errors, and the control loop might not be able to adjust to all the error at the speed required. Due the physical nature of certain control loop, it might take up to 100 seconds for optimization to be obtained again at the receiver. Therefore, it is necessary to keep track of the optimum settings even if you have very good BER at the moment. As an example, at a BER of 1e-15 and a bit rate of 10 GBit/s, only approximately one error will happen every day. This is not sufficient to keep track of the optimum settings of all control loops. By intentionally degrading the optical input signal, the BER can be set to an arbitrary level above the current value, thereby enabling the controller 134 to keep track of the optimum settings.
FIG. 3 depicts a flow diagram of a method according to an embodiment of the invention. As shown in FIG. 3 , parameters of the components of the system are adjusted to keep the control loops of the optical communications system in an active mode of operation. The data processing circuit 250 will monitor and report the BER of the received signal at the receiver 310 . If the received signal contains too many errors 320 , then the controller 134 will send the required feedback signal to the transmitter 110 , transmission link 120 , or the receiver itself in order for the receiver to continue to optimize the settings thereby improving the signal quality and reducing the number of received errors. If the received signal contains not enough errors in a certain interval (i.e. the BER is below the acceptable range), then the controller will offset one parameter of a control loop 340 to degrade the BER 350 . Some parameters that could be offset include the decision threshold, sampling phase, chromatic dispersion, polarization dispersion, and input/output power 360 . The parameter will be selected such that the BER will increase at the receiver. As a result, this action of degrading the BER will force the control loops to check the network 310 and ensure all components of the optical communications system is still operating at optimum 330 .
For example, one way to detect slow changes is to cause degradation using the CDRC. The controller can send a feedback signal modifying the decision threshold values at the CDR 240 . By changing the decision threshold to allow for more errors, the BER of the received signals will get worse. Now the amount of degradation needed to obtain a pre-set BER can be used for optimizing all other control loops (instead of using the BER itself). The controller 134 will perform its standard routine to ensure all the feedback control loop are optimized and allow for the optimal input signal to be received by the receiver. Through this process, acceptable minor drifts and other degradation will be compensated and/or corrected in a timely manner.
In an embodiment, a decision threshold is changed to induce an acceptable high BER for optimizing the other control loops. It is also possible that any other one or more of the control loops can also be used by the controller 134 to degrade the BER in order to obtain information on the optimum settings of the control loops. However, decision threshold control loop is a good loop to vary because the decision threshold can be changed very fast with respect to the system. Even after the decision threshold is shifted away from the optimal setting, the decision threshold can be quickly adjusted back to the previous optimal setting, and the input signal will still be received at substantially the optimal setting. Because of the physical nature of the system, the controller can vary the decision threshold quickly so the receiver will continue receiving input signal with minimal errors after the check.
Unlike the decision threshold control loop, a chromatic dispersion control loop may be a very slow control loop depending on the physical implementation. If that loop has drifted, then it might take up to 100 seconds to obtain the optimizing setting for the control loop. In a switched optical network, large amounts of errors could occur within the second right after switching. The FEC might not be able to correct all the errors received. The receiver will not know the new optimal chromatic dispersion setting. The FEC will fail and the transmission will be useless. The receiver does not have the luxury of up to 100 seconds to regain the optimizing settings for this control loop. The present invention will keep the chromatic dispersion control loop in an active state thereby preemptively tuning the parameters for chromatic dispersion.
Another embodiment involves obtaining the settings for an optimized input signal by degrading the input signal to get bit error without influencing the other control loops. For example, by changing the decision threshold some other control loops might be influenced. The receiver might compensate for shift in decision threshold by introducing some dispersion. This compensation by the receiver will cause the controller 134 to transmit improper feedback control signals causes the control loops to drift away from optimal. Therefore, it is important to find ways to degrade input signal without influencing the other control loops. One way to achieve this objective is to move the decision threshold very fast from the upper rail to the lower rail and back. This adjustment can be done very fast relative to the system. The effect of the fast shifting decision threshold will average out over time, and the other control loops will not notice the variation of the decision threshold.
FIG. 4 depicts a graphical representation useful in understanding the present invention. The graph shows a V-curve. The decision threshold is shown on the horizontal axis. It is an arbitrary value where zero is the optimal setting. On the negative side and positive side represent the degraded BER. On the vertical axis is the recorded BER. This graph represents the BER for a certain setting of the decision threshold, and at the same time, it shows a vertical eye opening. The vertical eye opening information, instead of the BER can be fed back to the other components of the system as feedback parameter to control the feedback control loops.
FIG. 4 defines the margin of the system and quality of the input signal. The left half of the “V” represents the lower threshold which is a line from −2 arbitrary units at 10 −12 BER to −10 arbitrary units at 10 −3 BER. The right half of the “V” is the line representing the upper threshold which is the line from 2 arbitrary units at 10 −12 BER to 10 arbitrary units at 10 −3 BER. The difference between the upper threshold and lower threshold is known as “vertical eye opening.” This parameter can be taken as the amount of dithering the threshold for signal degradation. One advantage of dithering the threshold is that the vertical eye opening linearly represents the system margin generally given in the unit decibel [dB]. When dithering the decision threshold from the upper rail to the lower rail and back, it is important to move the decision threshold in a way with certain fixed bit error rate. For example, if the upper rail is at decision threshold 6 , then the lower rail should be shifted to a decision threshold of −6. The decision threshold can be shifted between +6 and −6 arbitrary units, and the BER is 10 −6 . Once the input signal is intentionally degraded to a fix BER, then the BER should not be used to optimize other control loop. The vertical eye opening as a measure of the intentionally introduced degradation should be used as a feedback signal for the other control loops in this case.
In a different embodiment, the WDM signal received by the receiver may be degraded by loading the signal with optical noise. For example, EDFA could be used to introducing noise in the optical domain. Electrical noise could also be included to degrade the input signal. For example, this degradation could be accomplished by using an optical attenuator between the photodetector and the optical amplifier. The BER may also be degraded by setting one or more control loops on the receive side such as the already describe decision threshold. Also, degradation may be accomplished by adjusting to different sampling phase, offsets, chromatic dispersion, polarization mode dispersion, or other means to influence the optical signal on the receiver side. It is also envisioned that it might be advantageous to adjust a combination of the above parameters.
While the foregoing is directed to various embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. As such, the appropriate scope of the invention is to be determined according to the claims, which follow.
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Techniques to control an optical receiver having a control loop using Bit Error Rate (BER). In one implementation, a bit error rate (BER) associated with a received optical signal is determined. Indication of the BER to a control loop adapted is provided to adjust the optical signal in a manner tending to reduce the BER. The received optical signal is adapted in a manner tending to increase the BER such that the control loop operates within an active control region.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Design application Ser. No. 29/155,584, filed on Feb. 18, 2002 now U.S. Pat. No. D 471,727. This application also claims the benefit of U.S. Provisional Application No. 60/358,573, filed on Feb. 15, 2002. The above-identified applications are hereby incorporated by reference as if fully disclosed herein.
FIELD OF THE INVENTION
This invention relates to car seats, and more specifically relates to portable car seats sized to hold an infant or young toddler in the seat of an automobile that can also be converted to a wheeled stroller.
BACKGROUND OF THE INVENTION
Portable seats sized to hold an infant or young toddler in the passenger seat of an automobile, otherwise known as car seats, are well-known in the art. The purposes of these car seats is to protect the child and to properly position the child in the car seat for such protection. Car seats may also raise the level of the child slightly to allow a parent or guardian can administer to the child's needs more easily and perhaps to allow the child to see out of a car window. However, some car seats are bulky, lack versatility, and may not provide all the protection needed for the infant or child traveler.
SUMMARY OF THE INVENTION
The instant invention provides a light weight, versatile wheeled car seat that provides adequate protection for the passenger and can also be easily be converted to a stroller. The wheeled car seat is made from materials to protect the occupant while at the same time keeping the weight of the wheeled car seat to a minimum. When removing the wheeled car seat from an automobile, the user need not remove the child passenger while the user converts the wheeled car to a stroller. The user only need lift the car seat above the ground and allow a pivotal chassis to swing open and expose wheels to the ground, which also allows the user to convert the wheeled car seat from a car seat to a stroller without repositioning his or her hand and without losing grip. This feature eliminates the need for an adult to transport a stroller and a separate car seat in his or her car, thus saving precious trunk space. Also, the adult no longer has to disturb a youngster secured in a car seat by picking him up out of the car seat and placing him in a stroller. The wheeled car seat also employs an extendable handle so the user can push the wheeled car seat along the ground when it is in the stroller configuration. When the wheeled car seat is configured as a car seat, the wheels are enclosed to prevent dirt from getting on the upholstery of the automobile.
In one particular aspect of the present invention, a car seat capable of being converted to a stroller includes, a shell having a seat portion, a back portion, a side portion, and a bottom portion, a gripping surface, at least one wheel connected with the shell, and a pivotal chassis rotatably connected with the shell. The car seat can also include a mechanism for releasably holding the pivotal chassis in at least one position.
In another scenario of the present invention, a car seat capable of being converted to a stroller includes, a seat portion, a back portion, a first side portion, a second side portion, a rear portion, and a bottom portion, a gripping surface, at least one first wheel connected under the bottom portion, a pivotal chassis connected with an axle cylinder, wherein the axle cylinder is pivotally connected with the first side portion and the second side portion under the bottom portion, and at least one second wheel connected with the pivotal chassis. The car seat can also include a mechanism releasably engaging the axle cylinder to hold the pivotal chassis in at least one position.
In a further representation of the instant invention, a car seat capable of being converted to a stroller includes, a shell having a seat portion, a back portion, a first side portion, a second side portion, a rear portion, and a bottom portion, a gripping surface mounted on the first side portion and the second portion, at least a first wheel connected with the shell below the bottom portion, a pivotal chassis having a first arm and a second arm connected with a cross member, wherein the first arm and the second arm are connected with an axle cylinder and wherein the axle cylinder is pivotally connected with the first side portion and the second side portion, at least a second wheel connected with a bottom surface of the cross member, and a mechanism releasably engaging the axle cylinder to hold the pivotal chassis in a closed position wherein the bottom surface faces upward, an open position wherein the bottom surface faces downward, or an intermediate position.
The features, utilities, and advantages of various embodiments of the invention will be apparent from the following more particular description of embodiments of the invention as illustrated in the accompanying drawings and defined in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front left-side perspective view of a wheeled car seat.
FIG. 2 is a rear left-side perspective view of the wheeled car seat in FIG. 1 .
FIG. 3 is a right-side view the wheeled car seat depicted in FIGS. 1 and 2 in an automobile with a seatbelt holding the wheeled car seat in a position such that a child passenger would be facing the rear of the automobile.
FIG. 4 is a left-side view the wheeled car seat depicted in FIGS. 1 and 2 in an automobile with a seatbelt holding the wheeled car seat in a position such that a child passenger would be facing the front of the automobile.
FIG. 5A is a bottom left-side perspective sectional view of the wheeled car seat configured as a car seat.
FIG. 5B is a front view of a lower surface of a cross member of a pivotal chassis when the wheeled car seat is configured as a car seat.
FIG. 5C is a sectional bottom view of the wheeled car seat configured as a stroller detailing a detent.
FIG. 6A is a bottom right-side perspective sectional view of the wheeled car seat showing how a user actuates the detent.
FIG. 6B a front left-side perspective sectional view of the wheeled car seat showing a user's hand reaching through a detent hand slot.
FIGS. 7A–7C show the wheeled car seat being transformed from a car seat configuration to a stroller configuration.
FIG. 8 is a bottom view of the wheeled car seat in the stroller configuration.
FIG. 9A is a front left-side perspective view of a second embodiment of the wheeled car seat in the car seat configuration.
FIG. 9B is a front left-side perspective view of the second embodiment of the wheeled car seat in the stroller configuration.
FIG. 10 is a rear right-side perspective view of the wheeled car seat in the stroller configuration with a removable tote.
FIG. 11A is a front left-side perspective view of the wheeled car seat in a booster seat configuration.
FIG. 11B is a bottom view of the wheeled car seat showing an intermediate slot located in the axle cylinder.
FIG. 12 is a front right-side perspective view of a third embodiment of the wheeled car seat in the stroller configuration.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a front left-side perspective view a wheeled car seat 30 , and FIG. 2 shows a rear left-side perspective view of the wheeled car seat 30 in FIG. 1 . The wheeled car seat depicted in FIGS. 1 and 2 is shown in a car seat configuration. As discussed in more detail below, the wheeled car seat 30 may be reconfigured to function as a stroller. The shape of the wheeled car seat 30 is defined by a shell 32 . As shown in FIGS. 1 and 2 , the shell includes a seat portion 34 , a back portion 36 , a right side portion 38 , a left side portion 40 , a rear portion 42 , and a bottom portion 44 . The right side portion 38 and the left side portion 40 are mirror images of each other. Typically, a child seated in the wheeled car seat 30 rests his or her bottom on the seat portion 34 and his or her back against the back portion 36 . The right side portion 38 and the left side portion 40 of the shell provide side impact protection to a child passenger. When the child is seated in the wheeled car seat, the right side portion 38 and the left side portion 40 of the shell 32 will oftentimes be positioned adjacent the child's head, shoulder, and torso. In some instances, the side portions could absorb the impact from an exploding side door air bag or block flying glass and debris from striking the child passenger during an automobile accident.
As shown in FIGS. 1 and 2 , the right side portion 38 and left side portion 40 each have an interior surface 46 and exterior surface 48 and are defined by a bottom edge 50 , an arcuate front edge 52 , a rounded rear corner 54 , and a rear edge 56 . The rounded rear corner 54 is defined by the intersection of the right side portion 38 or left side portion 40 and the rear portion 42 of the shell. The bottom edge 50 extends between the rear edge 56 and the arcuate front edge 52 . The rear edge 56 extends upwardly from the bottom edge 50 to the rounded rear corner 54 . The arcuate front edge 52 extends upwardly from the bottom edge 50 and curves toward the rear portion 42 of the shell 32 until it intersects with the rounded rear corner 54 .
The shell 32 includes various openings or windows to allow a person to more easily grasp the wheeled car seat 30 when picking it up or maneuvering it into a desired position. Some of the openings or windows may also allow a child seated in the wheeled car seat to have a better view of his or her surroundings. For example, as shown in FIGS. 1 and 2 , a front upper opening 58 and a front lower opening 60 are located in the right side portion 38 and left side portion 40 of the shell. A first gripping area 62 is defined where the perimeter of the front upper opening 58 is nearest the arcuate front edge 52 . A second gripping area 64 is defined where the perimeter of the front lower opening 60 is nearest the arcuate front edge 52 . A third gripping area 66 is defined where the perimeter of the front upper opening 58 is nearest the perimeter of the front lower opening 60 . A person desiring to lift or maneuver the wheeled car seat 30 in an awkward environment, such as the back seat of an automobile, may find these numerous gripping areas useful.
Other openings may be located in the right side portion 38 and left side portion 40 to create additional gripping areas. For example, as shown in FIG. 2 , a rear upper opening 68 and a rear lower opening 70 are located in the ride side portion 38 and left side portion 40 of the shell 32 . A fourth gripping area 72 is defined where the perimeter of the rear lower opening 70 is nearest the rear edge 56 . A fifth gripping area 74 is defined where the perimeter of the rear upper opening 68 is nearest the rear edge 56 . It should be understood that the present invention may include more or less openings in the shell 32 with different shapes and sizes, and is not limited to what is depicted herein. However, the windows or openings should be located near one another or to the edges of the shell, so that the structural integrity of the of wheeled car seat 30 is sufficient to support being grasped. The stronger the shell material, the closer the openings can be to one another and to the edges.
As shown in FIGS. 1 and 2 , the wheeled car seat also includes an extendable handle mechanism 76 . The extendable handle mechanism 76 can be configured in a retracted position when the wheeled car seat is in the car seat configuration. The handle mechanism can also help to reinforce the structure of the wheeled car seat when the extendable handle mechanism 76 is in the retracted position. FIGS. 1 and 2 show the extendable handle mechanism in the retracted position. Alternatively, the extendable handle mechanism can be configured in an extended position when the wheeled car seat is in the stroller configuration, as is discussed in more detail below.
As shown in FIGS. 1 and 2 , the back portion 36 of the shell is generally defined by a surface area between an upper arcuate edge 78 and a rounded seat corner 80 . The upper arcuate edge 78 extends between the arcuate front edges 52 of the left side portion 40 and right side portion 38 . The rounded seat corner 80 extends between the interior surfaces 46 of the right side portion 38 and the left side portion 40 and is defined by the intersection of the back portion 36 and the seat portion 34 of the shell 32 . The seat portion 34 is defined by a rear seat portion 82 of the shell 32 between right side portion 38 and the left side portion 40 extending forward from the back portion 36 and sloping upward to a bend area 84 . From the bend area 84 , the seat portion 34 is further defined by a front seat portion 86 as the seat portion 34 extends forward and curves downward to an intersection of the front arcuate edges 52 and bottom edges 50 of the right side portion 38 and left side portion 40 . A front bottom edge 88 extends between the bottom edges 50 of the right side portion 38 and the left side portion 40 adjacent the front seat portion 86 . A detent hand slot 90 may also be located in the front seat portion 86 , as shown in FIG. 1 . The detent hand slot 90 serves as an additional gripping area as well as access to a detent 92 (not shown in FIGS. 1–2 ) discussed in more detail below.
The rear portion 42 of the shell 32 is generally defined by an area surrounded by a rear bottom edge 94 , the rounded rear corners 54 , the rear edges 56 of the right side portion 38 and the left side portion 40 , and the upper arcuate edge 78 . As shown in FIG. 2 , the rounded rear corners 54 extend downward from the upper arcuate edge 78 to the rear edges 56 of the right side portion 38 and the left side portion 40 . The rear edges 56 of the right side portion 38 and the left side portion 40 extend downward from the rounded rear corners 54 to the bottom edges 50 of the right and left side portions. The rear bottom edge 94 extends between the bottom edges 50 of the right side portion 38 and the left side portion 40 adjacent the rear portion 42 of the shell 32 . The rear portion 42 also defines an upper rear portion 96 and a lower rear portion 98 . As shown in FIG. 2 , a rear gripping slot 100 is located in the upper rear portion 96 . The lower rear portion 98 can also form a storage compartment 102 that can be closed by any suitable means such as a flap or an elastic cord net stretched across the lower rear portion 98 and secured to the right side portion 38 and the left side portion 40 .
The bottom portion 44 of the shell 32 is generally defined by a surface area underneath the seat portion 34 . As shown in FIGS. 1 and 2 , a pivotal chassis 104 is mounted to the shell 32 by an axle cylinder 106 extending between the right side portion 38 and the left side portion 40 and the bottom portion 44 . The pivotal chassis 104 is discussed in greater detail below.
FIGS. 3 and 4 show the wheeled car seat 30 configured as a car seat and secured in an automobile. In particular, FIG. 3 shows the wheeled car seat 30 secured to a rear seat 108 of the automobile by passing a seat belt 110 through the middle of the axle cylinder 106 such that a child seated in the wheeled car seat 30 would be facing the rear of the automobile. FIG. 4 shows the wheeled car seat 30 secured to the rear seat 108 of the automobile by passing the seat belt 110 through the lower rear opening 70 on the right side portion 38 of the shell 32 along the rear potion and exiting the lower rear opening 70 on the left side portion 40 of the shell such that a child seated in the wheeled car seat 30 would be facing the front of the automobile. Depending on the configuration of a particular seat belt, the shoulder harness of the seat belt could also pass through the upper rear opening 68 on one side of the wheeled car seat 30 and the lower rear opening 70 on the opposite side of the wheeled car seat 30 .
The wheeled car seat 30 may be constructed utilizing available technology to enhance the strength of the seat in order to protect the child passenger while at the same time providing a comfortable riding environment. For example, the wheeled car seat may be manufactured by utilizing similar techniques used in the manufacture of lightweight sports helmets, such as bicycle helmets. As is well known, bicycle helmets are made with essentially three layers. An outer most layer is a thin vacuum formed shell usually made from a high strength and lightweight plastic material such as polycarbonate or PET vacuum formable materials. A center layer or core of these materials typically comprises expanded polystyrene or other rigid but crushable cushioning materials. The core is usually attached to the shell using adhesives or hook and loop fasteners. A third layer, the inner most portion of bicycle helmets, comprises isolated textile pads which are held in strategic positions on the inside of the expanded polystyrene core with hook and loop fasteners.
Similarly, the present invention may employ many of these known helmet technologies by constructing the wheeled car seat using a strong, flexible, crushable, resilient layered approach. The shell 32 , as shown in FIGS. 1 and 2 , would comprise one or more vacuumed formed shell portions, which are assembled together using adhesives. In an alternative configuration, the axle cylinder 106 could hold two half-shelled portions together. The shell can be made utilizing various manufacturing techniques known in the art, such as injection-molding, blow-molding with a foam filled hollow core, and rotational molding. Immediately within the shell 32 would be a rigidifying and impact absorbing expanded plastic layer or core. While not shown, textile upholstery sections and cushioning sections for the seat portion and back portion of the wheeled car seat would be releasably attached using adhesives or hook and loop fasteners, and the like to the wheeled car seat. Because the cushioning sections would be releasably attached, they could be removed for cleaning or replaced when worn out without the having to replace the entire wheeled car seat. The strength of the shell material would help protect a child passenger in the event of an automobile accident, while at the same time providing a light weight design that can more easily be lifted or maneuvered.
The present invention could also utilize its own harness or seat belt restraint to better secure the child passenger to the wheeled car seat. For example, a car seat restraint could be equipped with a releasable buckle, similar to a standard automobile seat belt buckle as is known in the art, attached to a lower belt that is connectable to an upper harness. The lower belt could be affixed to the seat portion of the shell. The upper harness could be affixed to the back portion of the shell and includes a left strap and a right strap. The child passenger is secured to the wheeled car seat using the car seat restraint by passing the lower belt upward between the child passenger's legs and then buckling it to the upper harness after the left strap and right strap have been lowered across the child passenger's shoulders. Other car seat restraint configurations could include a waist strap secured to the back portion or seat portion of the shell that buckles across the child passenger's waist.
FIG. 5A is a bottom left-side perspective sectional view of the wheeled car seat 30 configured as a car seat. The pivotal chassis 104 includes a right pivot arm 112 , a left pivot arm 114 , and a cross member 116 . As previously discussed, the pivotal chassis 104 is connected to the shell 32 by an axle cylinder 106 extending between the right side portion 38 and the left side portion 40 under the bottom portion 44 . In particular, a first end 118 of the axle cylinder 106 penetrates the right side portion 38 and connects with a pivot area 120 of the right pivot arm 112 . Similarly, a second end 122 of the axle cylinder 106 penetrates the left side portion 40 and connects with the pivot area 120 of the left pivot arm 114 . Therefore, the axle cylinder rotates 106 with the pivotal chassis 104 . The cross member 116 extends between and is connected with the left pivot arm 114 and the right pivot arm 112 at a swing area 124 located on each pivot arm. As shown in FIG. 5A , the cross member 116 also has an upper surface 126 and a lower surface 128 . In an alternative configuration, the pivotal chassis could be secured to holes on the right side portion and the left side portion with a separate brace passing between the right and left side portions under the bottom portion of the shell.
FIG. 5B shows a front view of the lower surface 128 of the cross member 116 of the pivotal chassis 104 when the wheeled car seat 30 is configured as a car seat. As show in FIG. 5B , two cross member wheels 130 are mounted on the lower surface 128 of the cross member 116 of the pivotal chassis 104 . Two seat wheels 132 are mounted on a wheel axle 134 extending between the right side portion 38 and the left side portion 40 under the rear portion 44 of the shell 32 . When the wheeled car seat 30 is configured as a car seat, the cross member wheels 130 extend upwardly toward the bottom portion 44 of the wheeled car seat such that the cross member wheels 130 and seat wheels 132 are enclosed between the bottom portion 44 of the wheeled car seat and the lower surface 128 of the cross member 116 . This helps to prevent dirt from rubbing off the wheels and onto the upholstery of the automobile. As shown in FIG. 5B , the cross member wheels 130 are caster wheels, and the seat wheels 132 are fixed axis wheels with larger diameters. It should be understood that alternative wheel configurations may be used with different numbers, designs, and diameters, and the invention is not limited to what is depicted herein. For example, the wheels may be fixed axis or caster design, and a single wide roller or wheel could be used instead of a plurality of wheels. The cross member wheels 130 are mounted on the cross member 116 and spaced apart such that they do not interfere with the seat wheels 132 when the wheeled car seat 30 is configured as a car seat.
FIG. 5C is a detailed sectional bottom view of the wheeled car seat 30 configured as a stroller detailing the detent 92 used to hold the pivotal chassis 104 in closed and open positions. The detent 92 is comprised of a housing 136 attached to the bottom portion 44 of the shell 32 . The housing 136 maintains a sliding plate 138 with an engaging portion 140 and a handle portion 142 . As shown in FIG. 5C , springs 143 are attached to plate tabs 144 extending from the sliding plate 138 and to housing tabs 146 attached to the housing 136 such that a force exerted by the springs 143 operates to continuously pull the sliding plate 138 in a rearward direction toward the axle cylinder 106 . Therefore, the engaging portion 140 of the sliding plate 138 is continuously forced against the axle cylinder 106 by the springs 143 .
As shown in FIG. 5C , a first slot 148 and a second slot 149 are located on the axle cylinder 106 and are spaced approximately 180° apart. When the wheeled car seat 30 is configured as a car seat, the pivotal chassis 104 is in the closed position. Conversely, when the wheeled car seat 30 is configured as a stroller, the pivotal chassis 104 is in the open position. Therefore, when the engaging portion 140 of the sliding plate 138 engages the second slot 149 , the pivotal chassis 104 is held in the closed position, as shown in FIG. 5A . When the engaging portion 140 of the sliding plate 138 engages the first slot 148 , the pivotal chassis 104 is held in the open position, as shown in FIG. 5C . When the engaging portion 140 of the sliding plate 138 is not engaged in either slot, the pivotal chassis 104 is free to pivot, and the axle cylinder 106 is the center of rotation about which the pivotal chassis 104 rotates. Because the pivotal chassis 104 is connected with the axle cylinder 106 , the axle cylinder rotates together with the pivotal chassis 104 . As the pivotal chassis 104 and axle cylinder 106 rotate from one position to another, the engaging portion 140 of the sliding plate 138 is continuously pulled against the axle cylinder until the engaging portion 140 is aligned with either the first slot 148 or the second slot 149 . Once the engaging portion 140 of the sliding plate 138 is aligned with either the first slot 148 or the second slot 149 , the force exerted on the sliding plate 138 by the springs 143 pulls the engaging portion 140 into the slot, thus locking the axle cylinder 106 and pivotal chassis 104 into either the open position or closed position. It should be understood that the present invention is not limited to the detent design depicted and described herein. Other mechanisms could be employed to hold the pivotal chassis 104 in the open and closed positions without the need for the axle cylinder, while allowing rotation between these positions, such as a ratchet mechanism or releasable clasps that directly engage the right pivot arm 112 and the left pivot arm 114 , a rotating detent, and the like. In alternative embodiments of the present invention, no mechanism is utilized to hold the pivotal chassis in various positions. Instead, the pivotal chassis is allowed to pivot freely.
When a user wishes to convert the wheel car seat 30 from the car seat configuration to the stroller configuration, the user grasps the handle portion 142 of the sliding plate 138 of the detent 92 and pulls it in a forward direction until the engaging portion 140 of the sliding plate 138 is disengaged from the second slot 149 in the axle cylinder 106 , as shown in FIG. 6A . As shown in FIG. 6B , a user's hand 150 reaches the handle portion 142 of the sliding plate 138 of the detent 92 from outside of the wheeled car seat 30 through the detent hand slot 90 located in the front seat portion 86 .
FIGS. 7A–7C show one method of how a user can transform the wheeled car seat 30 from the car seat configuration to the stroller configuration. In FIG. 7A , a user is holding the wheeled car seat 30 above the ground by grasping the rear gripping slot 42 with her right hand and gripping the detent hand slot 90 with her left hand. Once the user grasps the handle portion 142 of the sliding plate 138 and pulls it forward until the engaging portion 140 of the sliding plate 138 is disengaged from the second slot 149 , the pivotal chassis 104 is free to rotate with the axle cylinder 106 in a counter-clockwise direction, as shown in FIG. 7B . The user then places the wheeled car seat 30 on the ground, forcing the pivotal chassis 104 to rotate further until the engaging portion 140 of the sliding plate 138 engages the first slot 148 in the axle cylinder 106 , as shown in FIG. 7C . The user then places the extendable handle mechanism 76 in the extended position, thus completing the reconfiguration of the wheeled car seat 30 to the stroller configuration.
As shown in FIG. 7C , the extendable handle mechanism 76 comprises a handle 152 attached to extendable handle support posts 154 . The handle support posts 154 can be configured to telescopically extend and retract. FIG. 7C shows the extendable handle mechanism 76 in an extended position, and FIGS. 7A and 7B show the extendable handle mechanism 76 in a retracted position. When the extendable handle mechanism 76 is in the retracted position, the handle support posts 154 are stored within the right side portion 38 and the left side portion 40 of the shell 32 . The extendable handle mechanism 76 may be locked in the retracted position by a handle latching mechanism as is common in the art. Locking the extendable handle mechanism 76 in retracted position allows a user to grasp the handle 152 when lifting the wheeled car seat 30 . When a user configures the wheeled car seat 30 to the stroller configuration, the user grasps the handle 152 and pulls the extendable handle mechanism 76 from its retracted position to its extended position. In an another embodiment, the handle support posts can be configured to pivot around the wheeled car seat such that the user can push the wheeled car seat either from behind or in front of the wheeled car seat.
FIG. 8 shows a bottom left-side perspective view of the wheeled car seat 30 in the stroller configuration. When the wheeled car seat 30 is in the stroller configuration, the wheeled car seat 30 is supported on the ground by the cross member wheels 130 and the seat wheels 132 . As shown in FIG. 8 , the cross member wheels 130 are caster wheels that add to the maneuverability of the wheeled car seat 30 . A user is able to push on the handle 152 of the wheeled car seat and steer by manipulating the direction of the cross member wheels 130 as the wheeled car seat 30 rolls along the ground. Other embodiments of the present invention can utilize seat wheels 132 that are caster wheels and cross member wheels 130 that are fixed axis designs. As previously discussed, a single wide roller or wheel could also be used instead of a plurality of wheels. Embodiments of the present invention may also employ a design where the rear portion 42 of the wheeled car seat presents a rounded, prow like configuration, as shown in FIG. 2 . This prow like configuration enhances the ability of a user to aim the wheeled car seat through crowded urban walkways when the wheeled car seat 30 is configured as a stroller.
Reconfiguring the wheeled car seat 30 to the car seat configuration from the stroller configuration works in an opposite manner as previously described with reference to FIGS. 7A–7C . The user places the extendable handle mechanism 76 in the retracted position, and holds the wheeled car seat 30 above the ground by grasping the rear gripping slot 42 with her right hand and gripping the detent hand slot 90 with her left hand. The user then grasps the handle portion 142 of the sliding plate 138 and pulls it forward until the engaging portion 140 of the sliding plate 138 is disengaged from the first slot 148 , allowing the pivotal chassis 104 to rotate in a clockwise direction, opposite of FIG. 7B . The user then places the wheeled car seat 30 on a surface, such as a seat in an automobile, so that the pivotal chassis 104 is forced to rotate until the engaging portion 140 of the sliding plate 138 engages the second slot 149 in the axle cylinder 106 , completing the reconfiguration of the wheeled car seat 30 to the car seat configuration. As shown in FIGS. 5A and 5B , the wheels are encased between the bottom portion 44 of the shell 32 and the lower surface 128 of the cross member 116 when the wheeled car seat 30 is in the car seat configuration. This helps to keep automobile seats relatively clean, because it is difficult for dirt accumulated on the wheels to rub off on the upholstery.
FIGS. 9A and 9B show a second embodiment of the present invention describing an alternative shell configuration and cross member design. Conversion of the wheeled car seat 30 depicted in FIGS. 9A and 9B from the car seat configuration to the stroller configuration works in substantially the same way as has been previously described. As shown in FIGS. 9A and 9B , the shell 32 of the wheeled car seat 30 has a single large opening 156 located in the left side portion 40 and one located in the right side portion 38 . A long gripping area 158 is defined where the perimeter of the large opening 156 is nearest the arcuate front edge 52 of the right side portion 38 and the left side portion 40 . A small opening 160 is located in the right side portion 38 and the left side portion 40 in a location near the intersection of the seat portion 34 and the back portion 36 . As shown in FIG. 9B , a foot rest 162 is located on upper surface 126 of the cross member 116 of the pivotal chassis 104 . When the wheeled car seat 30 is in the stroller configuration, a child passenger can rest his or her feet on the foot rest which can help prevent the child's feet from dragging on the ground.
As shown in FIG. 10 , the wheeled car seat 30 can be equipped with a removable tote 162 . The removable tote 162 is configured to be removably attached to the handle support posts 154 of the extendable handle mechanism 76 . The removable tote 162 depicted in FIG. 10 is sized to fit between the handle support posts 154 . The removable tote 162 can be attached to and hang below the handle support posts 154 by any known means. In FIG. 10 , the removable tote 162 is attached to the wheeled car seat 30 by spring loaded pins 164 that protrude from the removable tote 162 through pin holes 166 located in the handle supports 154 . The removable tote 162 shown in FIG. 10 is conveniently positioned between the user and child passenger at a comfortable access level, and can be used for carrying baby accessories and the like when the wheeled car seat 30 is in the stroller configuration. It should be understood that the removable tote could be secured in different ways and in other locations on the wheeled car seat, and is not limited to what is depicted herein. For example, the removable tote could be attached to the rear portion of the wheeled car seat using hook and loop fasteners. The removability of the tote allows the user to separate the weight of any bagged accessories from the wheeled car seat when lifting or maneuvering the wheeled car seat.
Embodiments of the wheeled car seat may also utilize other various shell and pivotal chassis designs so that the wheeled car seat could be employed for additional uses. For example, the wheeled car seat could be designed such that it could be used as a child's booster seat, as shown in FIG. 11A . When the wheeled car seat 30 is in the booster seat configuration, the pivotal chassis 104 is positioned in an intermediate position such that the rear portion 42 of the wheeled car seat 30 is elevated from the surface upon which it is resting. As shown in FIG. 11A , the wheeled car seat is supported by the front bottom edge 88 and the pivotal chassis 104 . In particular, support from the pivotal chassis 104 comes from the swing areas 124 of the right pivot arm 112 and the left pivot arm 114 along with the cross member 116 . As shown in FIG. 11B , an intermediate slot 168 is located in the axle cylinder 106 . When the engaging portion 140 of the sliding plate 138 engages the intermediate slot 168 , the pivotal chassis 104 is held in position such that the wheeled car seat 30 is secured in the booster seat configuration.
The bottom view of the embodiment of the wheeled car seat shown in FIG. 11B illustrates only one intermediate slot 168 located in the axle cylinder 106 . In addition, the detent 92 depicted in FIG. 11B is not spring loaded. Therefore, a user need not manipulate the detent 92 when converting the wheeled car seat from the car seat configuration to the stroller configuration and back again. In this configuration, the pivotal chassis 104 is free to rotate as previously discussed with reference to FIGS. 7A to 7C when the user lifts the wheeled car seat 30 above the ground. In another embodiments, the present invention could be configured with the first slot 148 , the second slot 149 , and the intermediate slot 168 located in the axle cylinder 106 . Depending on the desired functionality, the detent may or may not be spring loaded. In other embodiments, a plurality of intermediate slots could be located in the axle cylinder at various locations around its circumference, giving the user several choices of positions and elevations in which to place the wheeled car seat.
As shown in FIG. 11A , the right pivot arm 112 and left pivot arm 114 of the pivotal chassis 104 could also define a curved rocking surface 170 . This feature would allow the wheeled car seat 30 to rock back and forth on the curved rocking surface 170 when the wheeled car seat 30 is placed in the car seat configuration. Therefore, a person could rock a child seated in the wheeled car seat or the child seated in the wheeled car seat could rock the seat.
FIG. 12 shows yet another alternative wheeled car seat conforming to aspects of the present invention. This wheeled car seat is shown configured as a stroller. As shown in FIG. 12 , the wheeled car seat 30 includes seat wheels 132 and no cross member wheels. Because there are no cross member wheels, the cross member 116 could be supported by glides 172 . The glides 172 should be oriented on the cross member 116 such that they will not interfere with the seat wheels 132 when the wheeled car seat 30 is placed in the car seat configuration. The extendable handle mechanism 76 is also connected with the rear portion 42 of the wheeled car seat 30 . When a user desires to roll the wheeled car seat 30 , he or she grasps the handle 152 and tips the wheeled car seat 30 back until the pivotal chassis 104 is suspended above the ground, and then pushes or pulls the wheeled car seat 30 in the desired direction as it rolls on the seat wheels 132 . The wheeled car seat could also be configured with a gripping surface integral with the shell at a point where the user could push or pull the wheeled car seat. In an alternative configuration, the wheeled car seat could be configured with cross member wheels and no seat wheels. As previously discussed, the wheels may be fixed axis or caster design, and a single roller or wheel could be used instead of a plurality of wheels.
Although various embodiments of this invention have been described above with a certain degree of particularity or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to those disclosed embodiments without departing from the spirit or scope of this invention. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative only of particular embodiments, and not limiting. Changes in detail or structure may be made without departing from the basic elements of the invention as defined in the following claims.
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A wheeled car seat sized to hold an infant or young toddler in the seat of an automobile that can also be converted to a wheeled stroller is disclosed herein. The wheeled car seat is made from materials to protect the occupant while at the same time keeping the weight of the wheeled car seat to a minimum. When removing the wheeled car seat from an automobile, the user need not remove the child passenger while the user converts the wheeled car to a stroller, but instead only need lift the car seat above the ground and allow a pivotal chassis to swing open and expose wheels to the ground. When the wheeled car seat is configured as a car seat, the wheels are enclosed to prevent dirt from getting on the upholstery of the automobile.
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PRIORITY
This application claims priority under 35 U.S.C. §119 to an application filed in the Indian Patent Office on Aug. 24, 2006 and assigned serial no. 1518/CHE/2006, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of Communication Protocol in Long Term Evolution (hereinafter LTE) systems—Layer1 (Physical Layer), and more particularly, to a system and method for sub-frame IDentification (hereinafter ID) and Frame boundary detection in LTE.
2. Description of the Related Art
In the current specification document for Third Generation Partnership Project (3GPP) TR 25.814 v 7.0.0 (2006-06), three different options for radio frame timing detection are given as Synchronization CHannel (hereinafter SCH)-based detection, Broadcast Channel (hereinafter BCH)-based detection and reference signal-based detection.
The SCH-based detection is applicable to both hierarchical and non-hierarchical SCH. With SCH based detection, the radio frame timing can be estimated by detecting the cell-specific SCH sequence in the frequency domain employing the SCH symbol timing detected in a previous step. When primary and secondary SCH are used in the hierarchical SCH, coherent detection of the cell-specific secondary SCH can be performed using the primary SCH as a reference signal.
The BCH-based detection is also applicable to both the hierarchical and non-hierarchical SCH. For BCH-based frame-timing detection, the frame-timing is detected by decoding the BCH. This may include hypothesis testing if the BCH is transmitted less frequently than the SCH. This method requires BCH reception both for the initial cell search and neighboring cell search.
The reference signal-based detection is primarily considered for the hierarchical SCH. The frame timing information is detected by the reference signal waveform (i.e., modulation pattern). In this case, the repetition interval of the reference signal waveform should be equal to the radio frame period, or 10 milliseconds.
SCH based detection requires the detection of the cell-specific SCH sequence in the frequency domain employing the SCH symbol timing detected in the previous step. As many as 512 or more cell-specific SCH sequences need to exist, and also the UE will need to detect them by using processes such as correlation, which are time consuming. Moreover, the UE needs to store these cell-specific sequences.
BCH based detection requires the BCH reception for an initial cell search, which is not desirable. However, at this time the hypothesis testing if the BCH is transmitted less frequently than the SCH has yet to be completed.
Reference signal based detection has additional dependency on the reference signal waveform (i.e., modulation pattern) detection. Only upon reading of the reference signal contents may there be reliance on the timing in this method. Also, the reference signal waveform is only scheduled to be transmitted once per 10 milliseconds. Therefore, it imposes an additional delay in the frame boundary detection. The cell search procedure should be independent of any such signal waveform detection.
Commonly assigned US Patent Publication Serial No. US20030169702A1 to Ryu et al. describes a method of cell searching in a Wideband-Code Division Multiple Access (W-CMDA) mobile communication. According to the patent publication, an “index counter” is used to continuously calculate the timing offset or offset between frame boundaries. The index counter includes a “slot counter” and a “lower counter” which are used respectively for counting the slots and the chips corresponding to a length of a number of slots. Further, the Ryu et al. publication specifies that once the position of each asynchronous cell is determined by the slot counter, it is possible to calculate the offset between them wherein, the offset is defined as the difference between asynchronous frame boundaries. Moreover, the Ryu et al. publication describes that, using a similar process the lower counter may be able to calculate the offset between the slots corresponding to each frame. It is further mentioned in the Ryu et al. publication that such an algorithm is more time efficient for cell search.
U.S. Pat. No. 6,574,267 B1 to Kanterakis et al. describes an improvement to CDMA systems employing spread-spectrum modulation between a Base Station (BS) and a Remote Station (RS). The process starts with one RS receiving broadcast common—synchronization channel data, and after determining frame timing from the frame-timing signal, the signal is transmitted from a first RS-spread-spectrum transmitter as an access—burst signal. In the Kanterakis et al. patent, the BS notifies the RS about the correct receiving of the data packets. As an example, it has been specified in the patent publication that the packet could be identified as consisting of a number of frames, and sub-frames to the frames. The frames and sub-frames are identified by specific numbers. Further, the Kanterakis et al. patent describes that the correctness of the receiving of data packets could be achieved by identifying the frames and sub-frames carrying the data packets or by identifying the frames and sub-frames that have been received as error.
SUMMARY OF THE INVENTION
The present invention has been made to solve the aforementioned problems occurring in the prior art, and discloses a system and method wherein the need to use the SCH, BCH or the reference signals is obviated.
The method herein discloses a unique and easy way to identify the Frame boundary when there are multiple identical non identical SCHs in different sub-frames using a new method that will be referred to as “sub frame position difference method”. This method identifies the sub-frame ID based on the symbol/sub-frame difference between two sub-frames carrying the SCH symbol.
The present invention discloses a method that identifies the position of a slot/sub-frame or any data packet based on the differences between them. The present invention further discloses a system and method which can identify the slot/sub-frame or any data packet ID based on the difference, in time or number of slots/sub-frames or any data packets, between two subsequent slots/sub-frames or any data packets which may be identical to each other.
The present invention provides a unique manner of identifying the Frame boundaries in multiple identical non-identical SCHs in different sub-frames via the use of the sub frame position difference method, which implements the use of the differences between the different sub frames carried by the SCH. The sub frame identity, and hence the frame boundary, can be identified by calculating the difference between the positions (e.g., based on time or number of slots/sub-frames or any data packets) of the two subsequent slots/sub-frames or any data packets which may be identical to each other.
The present invention discloses a method for sub-frame ID and frame boundary detection in LTE, which method implements the use of the differences between the different sub frames carried by the SCH whereby the sub frame identity, and hence the frame boundary, is identified by calculating the difference between the positions of the two subsequent slots/sub-frames or any data packets which may be identical to each other.
The present invention discloses a system for sub-frame ID and frame boundary detection in LTE, which system implements the use of the differences between the different sub frames carried by the SCH whereby the sub frame identity, and hence the frame boundary, is identified by calculating the difference between the positions of the two subsequent slots/sub-frames or any data packets which may be identical to each other.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
The foregoing and other objects, features, and advantages of the present invention will become more apparent from the ensuing detailed description of the invention, taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates SCH symbols equally spaced, in which figure it is not possible to identify which sub-frame is received when all the SCH symbols are identical.
FIG. 2 illustrates four SCH symbols placed in frames 1 4 10 17 with a position difference of (3, 6, 7, 4) between the subsequent. SCH sub-frame, in which the sub-frame ID, and thus the Frame boundary, can be precisely identified from the SCH carrying sub-frame position difference between two such sub-frames.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will now be explained with reference to the accompanying drawings. However, it should be understood that the disclosed embodiments are merely preferred, and may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limiting but merely as the basis for the claims and as a basis for teaching one skilled in the art how to make or use the invention. A detailed description of known functions and configurations incorporated herein has been omitted herein for the sake of clarity and conciseness.
The LTE cell search procedure requires synchronization both in time and frequency and should be able to detect the frame boundary (or alternatively the sub-frame ID), so that the subsequent information in the downlink may be properly discerned. The synchronization procedure is completed with the help of SCH, which is carried in one or more sub-frames in an LTE system.
A small number of SCH symbols per radio frame are desirable in order to reduce the overhead. Furthermore, from the aspect of the timing detection performance against noise and interference, the signal energy of the SCH should be concentrated on a small number of Orthogonal Frequency Division Multiplexing (OFDM) symbols. However, time diversity employing multiple SCH symbols is very effective in achieving fast cell search by improving the detection probability of the SCH, particularly in a high mobility environment. Multiple SCH symbols per radio frame can also reduce the minimum required correlation detection period for SCH timing detection.
Therefore, one or more SCH symbols (typically two or four SCH symbols) mapping in a 10-millisecond radio frame is a utilized structure as shown in FIG. 1 . So, more than 1 SCH symbol in one radio frame is required. These symbols will be located in different sub frames.
The above requirement imposes the necessity to know the sub frame ID in order to know the frame boundary. To explain, the UE receives an SCH sequence and needs to know which sub frame is being transmitted currently. For example, if the SCH is transmitted in sub frame 1 , 6 , 11 and 16 in FIG. 1 , the UE needs to know the sub frame to which the received SCH belongs. Only then may the UE determine the current frame position and the frame boundary.
The present invention discloses the following method to receive the frame boundary:
The sub frame ID is explicitly signaled, for example using data bits in the SCH symbol which is not carrying the Primary SCH (hereinafter P-SCH).
When SCH symbols transmitted on different sub frames are not identical, the UE will come to know of the sub frame ID by using the corresponding (i.e., pre-stored) mapping between the received SCH and the sub frame ID.
When above signaling (i.e., point 1 ) is not possible, such as when data insertion in SCH symbols may not be a viable option and may disturb any property such as time-domain symmetry of the P-SCH, and more than one SCH transmitted are identical, the present invention discloses the sub frame position difference method.
In the sub frame position difference method, Frame Timing will be given by repeatability of SCH in a Frame, or the number of times SCHs occur in a frame.
In a Case 1, in which there is One SCH per Frame, only one SCH will directly indicate the position in the frame.
In a Case 2, in which there are Two SCHs per Frame, the frame boundary can be identified by repeating the SCH in any position except that in which the distance between them (hereinafter position difference) is 20/2=10. Specifically, the first and the second SCH may not be positioned in 1st and 11th place. Any other position difference, from 1-9, is valid.
In a Case 3, in which there are three SCHs per Frame, the position difference pattern will define the Frame boundary. Specifically, the position difference between any two subsequent SCHs will not be a constant. For example, the position differences can be arithmetically progressing.
Let the position difference pattern be 1, 3, 6, i.e. the sub frame containing SCH are expected to be at one of these three out of 20 available sub frames. When an SCH sub frame is received, we wait for the next SCH sub frame and if the difference between these two sub-frames is 2, then the first and the second SCH sub frame is received respectively. If the difference between these two sub-frames is 3, then the second and third SCH sub frames are received respectively. When the difference is greater than 3, the third SCH sub frame and the first sub-frame of the next frame are received respectively. Here, the constant position difference pattern cannot be used. The position difference pattern will be known in advance and will be unique.
The foregoing theory can be extended to n repeat SCHs in a Frame.
For example, in FIG. 1 if the UE received an SCH sub-frame and received another SCH sub-frame after 5 sub-frames; it does not indicate anything about the sub-frames position (i.e., sub-frame ID).
However, from FIG. 2 in which four SCH symbols are placed in frames 1 , 4 , 10 and 17 , it can be identified which SCH sub-frame was received prior to the current SCH sub-frame based on the number sub-frames received between them. For example, if the sub-frame difference between two SCH sub-frames is 7, then the two SCH sub-frames are at positions 10 and 17 , respectively.
To illustrate further the following combinations are valid:
1, 4, 8, 13—ok (3, 4, 5, 8)
1, 4, 8, 14—ok (3, 4, 6, 7)
1, 4, 8, 15—ok (3, 4, 7, 6)
1, 4, 8, 16—ok (3, 4, 8, 5)
1, 4, 9, 17—ok (3, 5, 8, 4)
1, 4, 10, 17—ok (3, 6, 7, 4)
Conversely, the following combinations are NOT valid:
1, 4, 9, 15—Not possible (3, 5, 6, 6)
1, 4, 9, 16—Not possible (3, 5, 7, 5)
1, 5, 10, 16—not possible (4, 5, 6, 5)
1, 5 10 17—not possible (4, 5, 7, 4)
1, 6, 11, 17—not possible all equally spaced (5)
1, 6, 12, 16—not possible (5, 6, 4, 5)
The foregoing combinations are only a few of the valid/not valid combinations. Also, to increase the probability of detection the SCH sub-frames should be as equally spaced from each other as possible. Although many combinations of SCH sub-frame position are possible, the one that retains the above-described property as much as possible, e.g., 1, 4, 8, 15, should be primarily considered.
Although the present invention has been fully described in connection with the preferred embodiments thereof with reference to the accompanying drawings, it is to be noted that various changes and modifications are possible and are apparent to those skilled in the art. Such changes and modifications are to be understood as included within the scope of the present invention as defined by the appended claims unless they depart there from.
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The present invention provides a unique manner of identifying the Frame boundaries in multiple identical/non-identical Synchronization Channels (SCHs) in different sub-frames via a new sub frame position difference method. The method implements the differences between the different sub-frames carried by the SCH. The sub frame identity, and hence the frame boundary, can be identified by calculating the difference between the positions, based on time or number of slots/sub-frames or any data packets, of the two subsequent slots/sub-frames or any identical data packets.
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FIELD OF THE INVENTION
This invention relates to power tongs for use in rotating drilling pipe and the like for the oil well industry as well as any other application where a pipe or cylindrical member has to be gripped. More particularly, it relates to a tong which is of improved construction.
BACKGROUND TO THE INVENTION
In the field of oil well drilling technology, power tongs are used to turn and make-up or break joints on tubing or drill rod as small as on the order of 1 inches in diameter, and on pipe or casing ranging up to 16 inches in diameter or more. Hereafter in this specification, all such tubing and rod whether for use in the oilfield or otherwise are collectively referred to as “pipe”.
As an example of a power tong of the type which may be re-adapted to employ the invention herein, reference may be made to U.S. Pat. No. 4,350,062, to Fan et al. This patent describes a power tong having a “C”-shaped power-driven rotary gear which turns within an outwardly containing tong body. The gap in the “C” serves as a throat through which pipe may be passed into the central body region of the tong.
The tong body also is “C”-shaped to allow pipe to be centered within the tong for rotation. While reference will be made to a “C”-shaped power tong in this disclosure, the invention is equally applicable to tongs that have a closed circular central opening through which pipe is inserted endwise.
The rotary gear within the tong body of a power tong has an inwardly-directed camming surface formed along its inner circular face. This cam surface generally provides two or more inwardly extending crescent-shaped circular wedge portions intended to help the gripping jaws engage with the pipe. The jaws are carried within a respective jaw carrier that includes a cam follower roller which rides along the cam surface, forcing the jaws inwardly until pipe is engaged. The outer circumference of the rotary gear contains gear teeth for engagement with a drive train mounted within the tong body to effect rotation of rotary gear, jaws and engaged pipe.
In operation the rotary gear drives one or more jaws carried in respective jaw assemblies, through the cam follower roller, into engagement with centrally-positioned pipe as the rotary gear begins to turn with respect to the tong body. The jaws within the jaw assemblies are contained between cage plates that cap the upper and lower sides of the central opening in the rotary gear. These cage plates “float” on the outer upper and lower surfaces of the tong body, free for partial rotation with respect to the rotary gear about their common center. The outer circumferential edges of the cage plates traditionally overlie the edges of the upper and lower plates of the tong body surrounding the central opening and the cage plates are free to rotate with respect to the tong body. They are constrained to remain centered but are free to rotate about the same axis as the pipe, but only for a portion of a full revolution with respect to the rotary gear until the jaw or jaws have engaged pipe. Thereafter the cage plates and jaw carrier or carriers and associated jaws rotate with the rotary gear. The camming surface and jaw carrier dimensions are selected to ensure pipe engagement and limit differential rotation between the cage plates and the rotary gear, generally to within less than a quarter-circle of rotation.
When the rotary gear first begins to turn after pipe has been placed in the center of the tong, a brake temporarily constrains the cage plates from rotating in conjunction with the gear. As the rotary gear commences to turn, the cam followers on the jaw assemblies are advanced radially inward by the camming surfaces of the rotary gear. This inward advancement arising from differential rotation between the cage plates with their jaws and the rotary gear continues until the jaws engage with the drill pipe. Further advancement of the cam followers up the inwardly advancing cam surfaces locks the jaws to the pipe and arrests further relative rotation between the cage plates and the rotary gear. Thereafter, the pipe is turned by the continued rotation of the rotary gear and jaw assemblies together, the force to effect rotation being transmitted through the jaws which are engaged with the pipe.
When the jaws are not in use, each jaw may be withdrawn from the central portion of the tong by the “parking” of each of the cam follower's rollers into a respective neutral recess formed in the inside surface of the rotary gear. Each such neutral recess is located adjacent to a beginning portion of the camming surface so that a cam follower's roller may retire into and nest within it. This allows the jaws to swing outwardly from the tong centre and frees the pipe to be slid inwardly or outwardly, through the throat in the “C”-shaped tong body, or to be inserted centrally in the case of a closed tong body.
The proper grasping of the drill pipe by the jaws depends on the relative rate of advancement of the jaws inwardly as the cam follower moves along the cam surface. The cam surface may be envisaged as a kind of curved wedge that is forced against the cam follower roller to urge the associated jaw inwards toward the pipe to is be gripped. As with a wedge, the rate of increase of the inward gripping force applied by the jaws as the cam follower moves up the cam surface will depend upon the steepness of the cam surface. This relative incline ratio of the cam surface may be characterized as the “camming schedule”.
Once the jaws have contacted the pipe, a relatively high radial force is applied to the pipe in order to ensure that a non-slipping, frictional engagement persists while torque is applied to the pipe. High torque forces are required to be applied to pipe in order to ensure that the joints in the drill pipe are properly made up, to break such joints, and to turn the drill pipe string where the boring of the earth is occurring if the power tong is used for such purpose. Such torque is applied to the rotary gear through a gear train that is typically driven by a hydraulic motor mounted on the tong body.
High radial forces are achieved by providing an appropriately powered hydraulic motor and gear train. As the camming surface is generally provided with a gradual inwardly-directed slope along which the camming roller is required to advance, as the jaws engage the pipe and are urged to force rotation of the pipe, a substantial spreading force is applied to the rotary gear along its inner camming surfaces. This outwardly directed force has to be contained. At the same time, it is important to ensure that the rotary gear continues to be free to rotate within the power tong body in engagement with the powered gear train. In particular, the rotary gear should be confined centrally within the power tong for rotation about the center of the central opening in the power tong throughout these actions.
Radial Containment of the Rotary Gear
Over a considerable range of torque values, the rotary gear of a power tong can be made sufficiently robust to resist outward expansion on its own. Nevertheless, a rotary gear needs to be constrained for rotation about a central location within the power tong body. For this reason, peripheral containment or rotary gear support rollers have traditionally been provided within the tong body.
In the past, to provide radial confinement for the rotary gear roller bearings have been provided that are mounted between the top and bottom covers of the tong body. Such roller bearings have in many cases been rotatably mounted within openings drilled in such covers. These rotary gear support roller bearings have been “dumbbell” like in shape and generally each dumbbell has been provided with two roller portions which extend around the gear teeth and engage against respective outward-directed circular track surfaces serving as races on the respective upper and lower sides of the ring gear. Such tracks have traditionally been located just above and below the gear teeth to support the rotary gear symmetrically about a central horizontal plane. An example of such a configuration is shown in FIG. 2 of U.S. Pat. No. 5,435,213, to Buck for a “Ring gear camming member” wherein the rollers 23 “bear against and contain a smooth surface 32 on ring gear 15, providing resistance to spreading when jaw members 4 are engaged with pipe 3”.
The roller bearings mounted inside the top and bottom covers of the tong body extend inwardly from the top and bottom inner surfaces of the cover plates to engage with a circular bearing surface on the rotary gear. The prior art configuration for supporting rotary gears has led to tongs of a significant thickness. Because the support rollers contact the rotary gear in pairs that embrace the centrally positioned gear teeth formed around the outer periphery of the rotary gear, such support roller pairs to take-up space between the rotary gear and the top and bottom on face plates. This increases the weight and/or cost of such tongs.
It would be desirable to establish a new configuration for supporting rotary gears which would allow a power tong to be built which is of reduced size and weight. This invention addresses that objective.
Specific Prior Art Rotary Gear Support
U.S. Pat. No. 4,827,808 to Haynes et al. issued May 9, 1989 for a “Rotor to assembly for power tong” describes a tong configuration wherein the rotary gear support rollers are mounted on the underside of the rotary gear, aligned to roll against a guide track carried by the bottom plate of the tong body. In particular, the support rollers are carried on posts or “stubs” protruding downwardly from the lower face of the rotary gear. The guide track contacted by the support rollers is fitted to the topside surface of the bottom cover of the tong body, and therefore the support rollers are located in the space between the rotary gear and the bottom cover. No portion of the rotary gear support rollers extends through the central opening defined by this bottom plate. An extension of the guide track is also carried by the gate at a location inwards from the levels of the tong covers. Additionally, this prior art reference is an example of providing a-symmetrical support for a rotary gear. The support rollers for the rotary gear as depicted are only present on the lower side of the rotary gear. Having cam followers on one side only as seen in this invention reduces the radial load carrying capacity of the rotary gear assembly and therefore limits applications but is nevertheless available as an option.
While U.S. Pat. No. 4,827,808 does describe a tong wherein a roller guide means for centering the rotary gear is mounted on the gear itself, nevertheless the thickness of the tong body of this configuration is increased by the fact that the rotary gear support rollers engage with the track fitted within the interior of the tong body, on the topside surface of the bottom cover of the tong body. This is particularly apparent in FIG. 3 of this reference which shows the extension of the guide track mounted on the inside surface bottom cover of the gate.
Central Alignment of the Cage Plates
Cage plates need to be centered on a power tong body as well. Cage plates can be centered on the tong either by guides mounted on the upper or lower covers of the tong body, or by guides provided by the rotary gear. In U.S. Pat. No. 5,819,604 to Buck, as seen in FIG. 3, rollers are fitted to the cage plates in a circumferential array. These rollers on the respective cage plates extend into receiving cavities, machined as accurate slots, formed in the top and bottom faces of the ring gear. These rollers keep the cage plates centered with respect to the rotary gear.
As an alternative to using rollers for centering the cage plate, Canadian patent 1,327,825 to McCoy et al, entitled “Track Supported Cage Plates for Power Tongs”, describes a rail and track combination as a centering means for a cage plate assembly. The rail is a circular ring formed on the outside of the tong body, and the track is a groove formed on the inside surfaces of the cage plates, or conversely. As described, the rail is preferably formed of a high-impact, abrasion resistant, low-friction elastomeric polymeric material, such as polyurethane.
Some form of centering arrangement for cage plates must generally be present in a power tong of this type. The present invention also addresses this objective.
Rotary Gear Support Across the Gate
In the standard “C”-shaped power tong, support rollers for the rotary gear are mounted in the body of the tong extending around the circular opening within the tong, from one side of the tong throat to the other. Support rollers are not generally included in the gate that closes such throat. In most applications, when the rotary gear turns in such tongs there is a portion of its outside periphery, adjacent to the throat of the tong, that is unsupported.
It would be desirable to provide support for the rotary gear in this region, namely in the region of the throat of the power tong. This invention addresses that objective.
Confinement of Rotary Gear Against Vertical Displacement
While peripheral roller bearings traditionally supply support to ensure the centering of a rotary gear in the plane of the gear, a rotary gear is also normally confined against vertical displacement within the tong body. In the past rotary gears have been confined by a bearing ring carried on the inside face of one or both of the cover plates of the tong body, as for example in U.S. Pat. No. 3,261,241 to Catland, items 48, 50, FIGS. 4, 5. This present invention addresses a further way to provide confinement for the rotary gear against vertical displacement within the tong body.
Gate Latch Mechanism
In a “C”-shaped power tong provided with a gate to close the opening or throat in the power tong, it is important to ensure that the gate is properly latched and secure before commencing operation of the tong. U.S. Pat. No. 4,827,808 to Haynes et al. depicts a latch 32 in FIG. 1. U.S. Pat. No. 6,082,224 to McDaniels, et al. depicts in FIG. 1A a feature described as “Safety interlock prevents tong from operating unless properly latched”.
The gate can be latched mechanically, in which circumstances it would be desirable to provide a detection mechanism to detect whether or not the gate is latched. Alternately, the latching of the gate can be effected by a power actuated latching system. In the past, such a hydraulically-based latching mechanism has relied upon hydraulic components located on the tong body adjacent to the gate or throat. This is an inconvenient location for either a power actuated latching system or a latch interlocked detection mechanism as this location makes such components vulnerable to collision with pipes and tools that may be present in the vicinity of the throat. It would be desirable to provide an arrangement by which a power actuated latching system or latching detection mechanism on a power tong is provided through components located at a more secure location.
The invention in its general form will first be described, and then its implementation in terms of specific embodiments will be detailed with reference to the accompanying drawings. These embodiments are intended to demonstrate the principle of the invention, and the manner of its implementation. The invention in its broadest and more specific forms will then be further described, and defined, in each of the individual claims which conclude this Specification.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a power tong is provided with a tong body having upper and lower tong body covers with a central opening, preferably circular and “C”-shaped but optionally closed, formed such that the covers contain a rotary gear between them. In order to maintain alignment of the rotary gear relative to the tong body, on at least one side of the rotary gear the rotary gear is provided with support in the form of a centering guide for the rotary gear which extends between the rotary gear and a tong cover, passing at least partially through the central opening formed in the tong cover. Such centering guide comprises a contacting surface interface that permit differential rotational motion between the rotary gear and the tong, including its covers.
The centering guide for the rotary gear according to the invention may be provided symmetrically on the upper and lower sides of the rotary gear. Alternately, the centering guide of the invention may be provided on only one side of the rotary gear, and alternate centering means, e.g. traditional or other innovative centering means, may be provided on the other side.
Optionally and preferably, a portion of the centering guide may extend outwardly from the rotary gear to the outside surface of one of the tong body covers to engage with a tong cover. This rotary gear originating portion of the centering guide may be in the form of rollers mounted on the rotary gear, or in the form of a circular ledge or rail mounted on the rotary gear. The contacting surface that permits differential rotational motion between the rotary gear and the tong in such case is preferably located along the inwardly directed edge face of the tong cover where it bounds the central opening of the power tong. Alternately such contacting surface may be located outwardly from the inwardly directed edge face of the tong cover. In such case, contact will be made against a surface carried on the outside of the tong cover generally proximate or adjacent to the perimeter of the central opening. Contact may alternately be made against rollers which extend outwardly from the face of the rotary gear. In such case, the rollers provide the contacting surface interface.
Preferably, providing symmetrical support to the rotary gear, the centering guide may include rollers mounted in the rotary gear with upper and lower roller portions extending outwardly from the rotary gear to engage simultaneously with such portions carried by the respective upper and lower covers of the tong body as previously described. These rollers may each be in the form of a cylindrical roller shaft mounted into the rotary gear through a bearing interface, the upper and lower roller portions extending outwardly from the rotary gear to respectively roll on the radially inwardly directed edge faces of the upper and lower covers of the tong body that define the perimeter of the central opening, or equivalent surfaces carried by such covers. Thus such edge faces, which serve as circular races, may be extended by an additional guide rail surface fastened to the outside surface of the associated cover. Alternately, the upper and lower roller portions may roll on the additional guide rail surfaces directly.
As an alternative to providing a centering guide in the form of rollers, for certain applications it is permissible for such a centering guide to effect a sliding contact between its two cooperating portions that provide the contacting surfaces that permit differential rotational motion. Thus the centering guide can include non-rotating posts, or even a rail or ledge that slides at the contacting surface. In such cases, provision of a low friction engagement between the sliding surfaces is desirable.
Preferably, when rollers are employed that are in the form of a unitary cylindrical roller shaft having ends which extend outwardly from the upper and lower sides of the rotary gear, the rollers can be journal mounted into the rotary gear, or can be mounted into the rotary gear through roller bearings. However alternately, similar shafts may be mounted to the rotary gear as posts fitted into the rotary gear and independent rolling elements fitted onto the ends of the respective posts on the upper and lower sides of the rotary gear. Such independent rollers can be journal mounted on such posts, or can be mounted on such posts through roller bearings. If post-mounted roller bearings are used, these may be of relatively larger diameter than the diameter of the posts.
Alignment of the Cage Plates
Whether rollers fixed guides are mounted on the rotary gear, the outer end portions or outwardly projecting extensions of such centering guide portions may align with a guide surface carried by the associated cage plate to provide a cage plate interface. Thus a radially outwardly or inwardly-directed circular cage plate guide surface may be formed on or proximate to the inside peripheral edge of the adjacent cage plate for contacting with outer end portions or extensions of the centering guides projecting outwardly from the rotary gear. These end portions or extensions then serve the dual purposes of centering the cage plate with respect to the rotary gear while permitting relative rotation between the cage plate and the rotary gear. In this variant, the rotary gear is centered by its connection to a tong cover through a centering guide, and the associated cage plate is centered by the rotary gear, sharing centering elements carried by the rotary gear that cooperate with the tong cover.
Alternately, the cage plate may, itself, be centered relative to the tong body by a cage plate centering guide which extends between the cage plate and a tong cover. Such cage plate centering guide also comprises a cage plate contacting surface interface that permits differential rotational motion between the cage plate and the adjacent tong cover. In particular, the cage plate may be centered relative to the tong body by a cage plate centering guide which extends between the cage plate and the inwardly directed edge face surface of the tong cover bounding the central opening in the tong. The centering of the cage plate in this configuration occurs without reference to the centering of the rotary gear within the tong.
As stated previously, it is permissible for the purpose of centering a cage plate within the tong for the cage plates to slide on such extensions, as rotation between a cage plate and the rotary gear generally only occurs prior to engagement of the tong jaws with pipe that is to be turned at a stage when high contact forces are not being generated.
According to another variant, the cage plate can participate in centering the rotary gear. In this case, the centering guide is divided up so that a first centering guide or guide portion is provided between a tong cover and an associated cage plate; and then a second centering guide is provided between the cage plate and the rotary gear. Thus the cage plate may include rollers that bear against a contacting surface on the associated tong cover, e.g. the edge face surface around the central opening. And the cage plate may include rollers that bear against a contacting surface on the rotary tong. Alternately, the rotary gear may carry rollers that bear against the contacting surface carried by the cage plate. Such first and second centering guides, e.g. rollers, extend respectively between a cage plate and a tong cover and between a cage plate and the rotary gear. These guides may be alternately mounted so as to be interspersed between each other. Furthermore, such second centering guide may be carried entirely by a cage plate, by the rotary gear or by a combination of both.
It is permissible to arrange that ½ of the support guides, e.g. rollers, are carried by the cage plate to engage with the rotary gear, and the other ½ are carried by the cage plate to engage with the tong cover. In such case the rollers can be mounted radially on the inside faces of the cage plates in an interspersed fashion, with alternate rollers engaging the tong cover and rotary gear. The ratio of support guides carrying out these two functions need not be 1:1. In this case again, support is being provided to the rotary gear through the central opening in the tong.
A feature of the invention is that it becomes possible to provide support for the rotary gear across the width of the gap that defines the throat in the tong body. This support for the rotary gear may be achieved by providing the door or gate that closes the throat of the tong body with a track to provide the contact surface and serve as a portion of the centering guide across the width of the throat. This track aligns with the contacting surface for the portion of the centering guide that is carried by the corresponding cover of the tong body.
An advantage of the design of the invention is that the rotary gear may be nearly the same thickness as, or not much thicker than, the thickness of the rotary gear teeth formed around the periphery of the gear. The structure needed to center the rotary gear is positioned through the central opening of the power tong. This permits the construction of a tong which is thinner and therefore of reduced weight.
The invention provides a tong of reduced thickness which permits one or more of the outer covers of the tong body to be integrated with a portion of the tong body sidewall. This may be achieved by machining the cover and sidewall from a single plate. Such machining can conveniently be done on one side only of the work piece that is to form the cover plate. This also allows a shallower tong, as the stresses induced into the tong body are distributed across the entire cross section of the plate, thus avoiding load transfer through the bolts and dowels penetrating the tong cover plates.
The smaller height profile of a power tong according to the invention enables the use of a bolt-through connection between the top and bottom covers, with no welding being employed and no tapped holes for connection of top and bottom covers. Additionally, blind holes can be machined into the inside surfaces of the covers to receive the ends of rotating shafts, particularly those associated with the transmission gear train present within the power tong. This reduces the need for retention mechanisms for gears as well as reducing the potential for contamination to arise from outside sources. Furthermore, this permits gear train shafts to be serviced easily without the necessity of individually unscrewing nuts or other connectors associated with each shaft.
Confinement of Rotary Gear Against Vertical Displacement
To confine the rotary gear against vertical displacement within the tong body, low friction bearing vertical confinement “buttons” can be fitted onto the inside surfaces of the tong body covers opposite complementary sliding face surfaces on the outer face sides of the rotary gear, and vice versa. Such buttons are conveniently fastened to the rotary gear or covers simply through holes drilled into such components. This provides a simpler arrangement than the provision of a low friction bearing ring carried on the inside face of one or both of the cover plates of the tong body or on the rotary gear. Nevertheless, vertical containment of the rotary gear can be provided in the form of a continuous ring of low friction material mounted to either the rotary gear or alternately on the body plates of the tong rather than providing a series of buttons.
Gate Mounted Track
A power tong wherein the tong body is a “C”-shaped and having a throat may generally include a gate for closing the throat. In such case, a track may be incorporated into the gate for engagement with portions of the centering guide that normally would extend between the rotary gear and a tong cover. Such a track is accordingly aligned with the contacting surface for the centering guide that is carried by the corresponding cover of the tong body when the gate is in a closed position.
Gate Latch Mechanism
In order to either latch the gate on a “C”-shaped power tong, or provide a detection mechanism to detect whether or not the gate is latched, such latching of the gate or latch status detection can be effected by a remote actuator or sensor connected to the gate through an optionally spring loaded push cable that is confined laterally so that it can be retracted or advanced along its length to apply a force or effect a displacement at a distance. While described as a “push cable”, such a cable can optionally transmit a force in both directions, providing a push, pull function.
An example of one cable arrangement to achieve this effect is that of “Bowden cable”. Bowden cable, invented by and named after Ernest Monnington Bowden (1860 to 1904) relies on an inner flexible cable, the “push cable”, confined within an outer flexible sheath. As an alternative to the use of such a sheathed cable, lateral confinement of a push cable within the power tong according to the invention may be achieved by machining a confining groove of appropriate dimension into the inner surface of one of the tong body covers where two such surfaces meet to provide a thickened wall portion for the tong. The side walls of this groove then serve the same function of the outer sheath utilized in Bowden cable. The containing surface over this groove is provided by a portion of the other cover that overlies the groove.
The foregoing summarizes the principal features of the invention and some of its optional aspects. The invention may be further understood by the description of the preferred embodiments, in conjunction with the drawings, which now follow.
Wherever ranges of values are referenced within this specification, sub-ranges therein are intended to be included within the scope of the invention unless otherwise indicated. Where characteristics are attributed to one or another variant of the invention, unless otherwise indicated, such characteristics are intended to apply to all other variants of the invention where such characteristics are appropriate or compatible with such other variants.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the power tong according to the invention with the top tong body cover removed, exposing the rotary gear and transmission gears, and with the cage plate aligned with the throat formed in the rotary gear and bottom cover of the power tong. This view shows the single hanger bar for supporting the tong.
FIG. 2 is a plan view of the power tong of FIG. 1 with both the top tong body cover and the top cage plate removed exposing the rotary gear and transmission gears and with the bottom cage plate aligned with the throat formed in the bottom cover of the power tong.
FIG. 3 is a plan view of the power tong as in FIG. 2 with the rotary gear partially rotated with respect to the tong body from the position of FIG. 2 .
FIG. 4 is a longitudinal cross-sectional view taken along the centerline of the power tong of FIG. 3 . FIG. 4 also shows a gate that incorporates an alignment track.
FIG. 4A is a longitudinal cross-sectional enlarged view taken through a roller of the power tong of FIG. 3 .
FIG. 5 is a top view of the power tong of FIG. 1 with the top tong body cover and top cage plate both present.
FIG. 6 is a side view of the power tong of FIG. 5 .
FIG. 7 if is a bottom view of the power tong of FIG. 5 .
FIG. 8 is a cross-sectional perspective view through the center of a power tong as in FIG. 1 showing rollers mounted on the rotary gear bearing against the inside edge face of the circular opening formed in the top cover plate.
FIG. 9 is a cross-sectional view as in FIG. 8 wherein the rollers have been replaced by rails which are formed as unitary extensions of the rotary gear and which rails bear against rollers mounted on the outside covers of the power tong.
FIG. 10 is a cross-sectional view as in FIG. 9 wherein the unitary rails have been replaced by rails which are fastened to the rotary gear.
FIG. 11 is a cross-sectional view as in FIG. 9 wherein the upper rail bears against an outer guide fastened to the top face of the cover plate which serves as an extension of our alternative to the edge face surface of such cover plate to provided radial containment of the rotary gear.
FIG. 12 is a perspective view of a closed throat variant of the power tong according to the invention with the top tong body cover shown in partial cross-section, thereby showing the rotary gear with cylindrical rollers and low friction bearing support buttons.
FIG. 13 is a view of an alternate variant on FIG. 12 where a continuous vertical deflection support ring is provided as an alternative to the low friction bearing support buttons.
FIG. 14 is a radial, vertical cross-sectional view taken through two alternate roller configurations for rollers carried respectively by the upper and lower cage plates. The upper roller contacts the rotary gear and the lower roller contacts the adjacent surface of the lower cover plate.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the Figures a power tong has a tong body 1 with upper 2 and lower 3 tong body covers with a central opening 4 , preferably a circular “C”-shaped opening with a throat 5 , formed in such covers 2 , 3 . The covers 2 , 3 contain a rotary gear 6 between such covers 2 , 3 .
The tong has a gate 7 for closing the open throat, a hydraulic motor, 8 and a transmission gear train 9 extending between the hydraulic motor 8 and the rotary gear 6 . The outer periphery of the rotary gear 6 is provided with gear teeth 10 which engage with corresponding gears of the transmission gear train 9 .
Attached to the lower cover 2 of the tong body 1 at a point along or near a vertical line extending from its center of mass is a sling member 14 . This sling member 14 is preferably in the form of a twisted or welded bar having at its upper end a transverse opening 30 extending in the direction transverse to the major length of the power tong. The upper inner boundary of the opening 30 has a series of detents 31 . At its lower end, the sling member 14 is connected to the tong body 1 through a shackle member 32 providing a hinged connection having a hinge pin with a hinge axis. The series of detents 31 are aligned in a direction which is substantially parallel to such hinge axis and allow connection of the sling member 14 to a suspending chain or cable at alternate locations. This alignment of the detents 31 permits adjustment of the orientation of the tong body 1 about the longitudinal axis of the power tong.
The shackle includes two upright sidewalls that embrace the end of the supporting member. These sidewalls contain an arcuate slot that is penetrated by bolt passing through a hole in the supporting member. Adjustment of the alignment of the supporting member with the arcuate slot, followed by clamping the bolt type, will allow the orientation of the tong to be adjusted about an axis which is the same as the hinge axis.
As shown in FIGS. 1-4 the outer covers 2 , 3 of the tong body 1 are integrated with the tong body sidewall 11 by being respectively machined respectively from a single plate. Bolts 13 connect the top and bottom covers 2 , 3 . Blind holes (not shown) are machined into the inside surfaces of the covers 2 , 3 to receive the ends of shafts, particularly those associated with the transmission 9 present within the power tong body 1 .
Centering of the Rotary Gear:
As shown in FIGS. 2-4A , cylindrical rollers 15 are journal mounted into the rotary gear 6 to provide alignment of the rotary gear 6 relative to the tong body 1 . The outer portions of such rollers 15 at both ends bear against the respective inside edge face surfaces 16 of the top and bottom cover plates 2 and 3 surrounding the central opening 4 to provide a centering guide for the rotary gear 6 . Thus such rollers 15 extend on their upper portions through the central opening 4 outwardly past the inside surface of the top cover 2 .
In FIG. 8 separate rollers 15 A are mounted on pins passing outwardly from the rotary gear 6 to engage with the edge face 16 of the top and bottom cover 3 . Such rollers 15 A are mounted to the pins through roller bearings.
In FIG. 9 the rollers 15 , 15 A are replaced by two circular rails 17 extending upwardly and downwardly from the ring gear 6 to engage with cover-mounted rollers 18 positioned on the outside surface 2 B, 3 B of the top and bottom cover plates 2 and 3 . In FIG. 9 the rails 17 are unitary portions of the ring gear 6 .
In FIG. 10 a pair of alternate circular rails 17 A are fastened, as by being bolted, to the rotary gear 6 . These circular rails 17 A bear against the inside edge face surfaces 16 of the top and bottom covers 2 , 3 along a sliding interface which serves as the contact surface.
In FIG. 11 the upper of the two unitary circular rails 17 extends upwardly beyond the outside surface of the upper cover 2 to engage with a cover-mounted guide 20 positioned on the outside top surface 2 B of the top cover 2 . While only a single upper guide 20 is shown in FIG. 11 , a second lower guide 25 for the rotary gear 6 may be provided on the outside face of the lower cover 3 , with suitable alternate centering structure provided for the lower cage plate 21 .
FIG. 4 shows a gate 7 closing the throat 5 of a “C”-shaped power tong. A track 45 is incorporated into the gate 7 for engagement with portions of the centering guide, e.g. rollers 15 , 15 A that normally would extend between the rotary gear 6 and a tong cover 2 , 3 . Such a track 45 is aligned with the contacting surface 16 for the centering guide that is carried by the corresponding cover 2 , 3 of the tong body 1 when the gate 7 is in a closed position.
Alignment of the Cage Plates
Upper and lower cage plates 22 , 21 are maintained in central alignment with the tong body 1 as shown in FIGS. 4 and 8 by contact between a radially outwardly directed circumferential surface 23 forming part of a centering track on the cage plates 21 , 22 , and the outwardly extending portions of the rollers 15 , 15 A. In FIG. 9 the rail 17 is shown contacting such a circumferential surface 23 on the lower cage plate 21 .
In FIG. 10 , the alternate rail 17 A contacts the radially outwardly directed circumferential surface 23 of the cage plates 22 & 21 as well as the inwardly directed edge face surface 16 in the cover plate 2 , 3 .
In FIG. 11 containment of the lower cage plate 21 is provided by contact between the cage plate surface 23 and the lower rail 17 of the rotary gear 6 , supplemented by a lower cover-mounted guide 25 positioned opposite the outer peripheral edge 26 of the lower cage plate 21 . The rail 17 in FIG. 11 is shown as being a-symmetrical between its top and bottom portions. A cage plate mounted on the top (not shown), would not be confined by a supplementary cover-mounted guide in this configuration.
A differential “sliding” (rather than rolling) of the centering guide contacting surfaces on the cage plates 21 , 22 over or against rollers 15 , 15 A that rotate in order to support the rotary gear 6 is acceptable under many applications. In such case the cage plates 21 , 22 may be said to be maintained in a “floating” confinement by sliding against the rollers 15 , 15 A. While not ideal, when the highest torques are being transmitted to the rotary gear 6 virtually no differential motion occurs between the rotary gear 6 and the cage plates 21 , 22 . When the rotary gear's requirement for support is greatest (high static loads), no significant differential movement in the chain of parts delivering the force e.g. no rolling, occurs. Where “skidding” at the contacting surfaces does occur, it is preferable to provide enough clearance between the parts to prevent scoring or jamming.
Cage Plates Support for the Rotary Gear
In FIG. 14 the cage plates 21 , 22 actually participate in centering the rotary gear 6 . While in FIG. 14 two alternate roller configurations for rollers 41 , 40 carried respectively by the lower and upper cage plates 21 , 22 are in apparent alignment with each other, the central dividing line 42 in this figure has been inserted to indicate that this is not necessarily a single cross-section. FIG. 14 can represent a single cross-section, but can also represent a composite cross-section taken along different radial planes. According to this latter interpretation, the bottom roller 41 can actually correspond to rollers interspersed between top rollers 40 as shown in the upper half of the figure.
In FIG. 14 the upper roller 40 contacts the rotary gear 6 and the lower roller 41 is, according to this interpretation, exemplary of an adjacent upper roller (not shown) that contacts the edge face surface 16 of the top cover 2 . The actually depicted upper roller 40 acts as a first centering guide between the rotary gear 6 and an associated upper cage plate 22 ; and the corresponding adjacent upper roller (not shown—that is exemplified by the lower roller 41 ) acts as a second centering guide between the upper cage plate 22 and the top cover 2 . Thus such first and second centering guide portions, e.g. rollers 40 , 41 , extending respectively between a cage plate 22 and the rotary gear 6 and between a cage plate 22 and the edge face surface 16 of the associated cover. The general effect of this arrangement is that the cage plate 22 participates as part of the centering guide for the rotary gear 6 .
While the rollers 40 , 41 of FIG. 14 which constitute the first and second centering guide portions are shown as each being carried on a cage plate 22 , 21 , the cage plates 21 , 22 may carry rollers 40 which exclusively contact the tong covers 2 , 3 and the rotary gear 6 may carry rollers similar to rollers 15 that engage with a ledge or track formed on the cage plates 21 , 22 . In such case the first and second centering guide portions comprise rollers that are respectively carried on the cage plate and on the rotary gear.
As a further alternative, a tong can be built having only a second centering guide portion, e.g. a roller 41 carried by a cage plate 21 . In this configuration a tong is provided wherein all of the rollers 40 , 41 mounted in both the upper and lower cage plates 21 , 22 are positioned according to the position of the lower roller 41 shown in FIG. 14 . The support for the rotary gear 6 passes, not through the cage plate 21 , 22 , but through rollers 41 held by the cage plate 21 . The same rollers 41 may contact both the edge face 16 of the cover plate 3 and a shoulder 43 on the rotary gear 6 , optionally sliding on one of them.
Confinement of Rotary Gear Against Vertical Displacement
To confine the rotary gear 6 against vertical displacement within the tong body 1 , multiple low friction, bearing support “buttons” 28 are attached to the outer top side surfaces of the rotary gear 6 as shown in FIGS. 3 , 12 and 14 . These buttons 28 bear against a complementary surface formed on the inner underside surface of the upper cover plate 2 . A similar mirror image arrangement is present on the underside of the rotary gear 6 .
Two alternate arrangements are shown in FIGS. 3 and 14 wherein cover-mounted support buttons 29 are positioned on the inner face of the lower tong cover 2 to bear against a complementary surface formed on the underside surface of the rotary gear 6 . On the top side of the rotary gear 6 buttons are carried by the gear 6 and the complementary face surface is formed on the underside surface of the upper tong cover 2 . While both rotary gear-mounted and cover-mounted buttons 28 , 29 are both shown in FIG. 3 , one of either of these alternatives may be employed exclusively to confine the rotary gear 6 against vertical displacement on both its upper and lower faces.
Gate Latch Mechanism
In order to either latch the gate on a “C”-shaped power tong, or provide a detection mechanism to detect whether or not the gate is latched, such latching of the gate or latch status detection can be effected by a remote actuator or sensor connected to the gate through a push cable that is confined laterally so that it can be retracted or advanced along its length to apply a force or effect a displacement at a distance. While described as a “push cable”, such a cable can optionally transmit a force in both directions, providing a push, pull function.
An example of one cable arrangement to achieve this effect is that of “Bowden cable”. Bowden cable, invented by and named after Ernest Monnington Bowden (1860 to 1904) relies on an inner flexible cable, the “push cable”, confined within an outer flexible sheath. As an alternative to the use of such cable, lateral confinement of a push cable within the power tong according to the invention is achieved by machining a confining groove of appropriate dimension into the inner surface of one of the tong body covers. The side walls of this groove then serve the function of the outer sheath utilized in Bowden cable. Preferably, a surface provided by the other cover also provides confinement.
CONCLUSION
The foregoing has constituted a description of specific embodiments showing how the invention may be applied and put into use. These embodiments are only exemplary. The invention in its broadest, and more specific aspects, is further described and defined in the claims which now follow.
These claims, and the language used therein, are to be understood in terms of the variants of the invention which have been described. They are not to be restricted to such variants, but are to be read as covering the full scope of the invention as is implicit within the invention and the disclosure that has been provided herein.
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A power tong body having a central opening comprises upper and lower cover plates and a rotary gear contained there between. The tong incorporates the centering guide, e.g. rollers, that extend between the rotary gear and respective tong covers. Such centering guides through the central openings in the tong body covers and provide contact surfaces carried that permit differential rotation of the rotary gear with respect to such covers. The rollers may roll on circular races formed by the inside edge face surfaces of the tong covers bordering the central opening. The support rollers may also extend beyond the upper and lower cover plates and engage with a guide surface or race formed on the respective cage plates of the tong, centrally locating such cage plates with respect to the rotary gear while allowing differential rotation of the cage plates with respect to the rotary gear.
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BACKGROUND OF THE INVENTION
It is common practice to cover a surface or structure with sheet material for decoration, protection or reinforcement. A few examples of these applications include wallpapering and covering models of planes, boats, cars and such with a sheet material. When covering models the sheet material can be used to form a surface over a series of spaced planar ribs or bulkheads arranged to form a particular shape or contour. It is also used to cover an already existing surface of any shape or contour.
With such applications it is most desirable to trim sheet material at a uniform predetermined distance from an inside or outside line of intersection of two surfaces. This uniform line of overlap helps to ensure a lasting and aesthetically pleasing application.
At present, few tools are available for such cutting operations and they have very little adjustability. As a result, many modelers resort to gluing individual hobby blades to rectangular balsawood sticks of a certain thickness to achieve the desired overlap.
SUMMARY OF THE INVENTION
The invention is a sheet material cutting tool including a body defining a bottom guide surface; a front surface; a channel extending transversely to the bottom guide surface and intersecting the front surface; and a first leg and a second leg straddling the channel and each forming a portion of the bottom guide surface. The body also includes at least one slot defined by the first and second legs and transversely intersecting the channel, the slot being parallel to the bottom guide surface and shaped to receive the shank of a blade; and a closure actuatable to produce a force clamping the shank between the legs.
According to certain features of the invention, the front surface is convex and, radially intersected by the slot; the front surface is symmetrical around the slot; and the body has a top guide surface parallel to the bottom surface. These features facilitate desired material trimming with the tool.
According to other features of the invention, the first and second legs define a rectangular cavity for receiving the shank and the slot includes a rear portion extending rearwardly of the cavity; and the closure includes a tightening mechanism extending between the first and second legs and through the rear portion of the slot which further includes a fan-shaped portion extending between the cavity and the front surface and a transversely enlarged opening terminating an inner end of the rear portion and extending between the top surface and the bottom surface. These features further facilitate desired use of the tool.
According to an important feature of the invention, the tool includes a plurality of the slots. The plural slots greatly increase the functional flexibility of the tool.
DESCRIPTION OF THE DRAWINGS
These and other objects and features of the invention will become more apparent upon a perusal of the following description taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a right hand isometric view of the blade holder tool invention;
FIG. 2 is a left hand isometric view of the blade holder tool invention;
FIG. 3 is an exploded partial longitudinal cross section taken along lines 3 — 3 of FIG. 1 exposing a typical receptacle slot;
FIG. 4 is a partial longitudinal cross section identical to FIG. 3, but shown fully assembled;
FIG. 5 is a partial longitudinal cross section identical to FIG. 4 but with the blade shown in the “clamped” position;
FIG. 6 is a partial isometric view similar to FIG. 1 with the blade shown installed in a right hand position;
FIG. 7 is a partial isometric view similar to FIG. 6, but with the blade shown in a left hand position;
FIG. 8 is a side view of the blade holder illustrating an important feature of the invention's design:
FIG. 9 is a front elevation illustrating the arrangement of the slots and their spatial relationship to the guiding surfaces;
FIG. 10A is a top view of the invention during a cutting operation illustrating one type of “on the fly” adjustability;
FIG. 10B is a view similar to FIG. 10A illustrating a second type of “on the fly” adjustability;
FIG. 11 is a side elevation illustrating a cutting operation at an “outside” edge whereby sheet material is severed precisely at a uniform predetermined distance from the line of intersection of two surfaces;
FIG. 12 is a side elevation illustrating a cutting operation at an “inside” edge whereby sheet material is severed precisely at a uniform predetermined distance from the line of intersection of two surfaces;
FIG. 13 is a side elevation illustrating a cutting operation performed by slidingly guiding the tool tangentially on a rounded corner of a structure severing sheet material precisely at a uniform predetermined distance of overlap;
FIG. 14 is a side elevation illustrating the tool being used to cut “pinstripes” with the aid of a straightedge;
FIG. 15 is an isometric view of the blade holder tool being used to cut freehand or non-linear “pin-striping”; and
FIG. 16 is an isometric view illustrating the blade holder tool being used to cut a shape with a uniform width or border.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-5, a multi-receptacle blade holder tool 1 consisting of a body 10 generally rectangular in cross section, having a handle portion 12 and a rounded multi-receptacle end 14 . The end 14 includes a clamping means 16 comprised of a relief channel 18 which bifurcates end 14 into two portions or legs 16 a and 16 b which generally form clamping means 16 . The end 14 also includes a plurality of receptacle slots 20 arranged in a stacked configuration for receiving and clamping in place typical # 11 hobby blades 34 . As seen in FIG. 3, the slots 20 consist of an opening 20 a, a wide slot portion 22 to accommodate blade shoulder 36 , and a narrow slot portion 24 to accommodate blade shank 38 and end wall 24 c which limits the insertion of blade 34 to a predetermined distance. The slots 20 are further defined by upper and lower surfaces 26 a and 26 b, respectively, which are spaced in tight tolerance to blade 34 's thickness to ensure a secure fit when a blade is clamped into position. The slots 20 which are also bifurcated by channel 18 include two opposing clamping surfaces 24 a and 24 b at the narrow portion 24 of slot 20 . Leg 16 a has a counter-sunk threaded bore 28 a while leg 16 b has a non-threaded bore 28 b . A flat head machine screw 30 a is threaded into bore 28 a until it is fully tightened and flush with outer surface 16 c of leg 16 a. It passes through bore 28 b of leg 16 b with no engagement and protrudes perpendicularly from surface 16 d of leg 16 b. A thumbnut 30 b is threaded onto the protruding threads of screw 30 a until it contacts surface 16 d of leg 16 b. To use the blade holder 1 , a blade 34 is then inserted into receptacle slot 20 until the end of blade shank 38 c contacts end wall 24 c of slot 20 . When thumbnut 30 b is tightened further, shown as force arrow A, it begins to pinch legs 16 a and 16 b together, shown as force arrows B, as they flex at areas 18 a and 18 b facilitated by relief channel 18 and relief bore 19 . When this flexing occurs, blade 34 is clamped between surfaces 24 a and 24 b at edges 38 a and 38 b of blade shank 38 . This clamping method is capable of holding a single blade or multiple blades in any number of positions to achieve many different desired tool configurations. The blade holder 1 is purposefully designed to have smooth friction free surfaces and radius edges for a comfortable feel and more importantly to protect any adjacent surfaces, structures or materials from damage when blade holder 1 is in use.
As can be seen in FIGS. 6 and 7, the blade holder 1 is purposefully designed to be symmetrical and to be able to hold blades 34 in either a right or left handed configuration. This combined symmetry allows the blade holder 1 to be used by right and left handed users without sacrificing functionality or ergonomics. It also allows the blade holder 1 to perform opposite or symmetrical cutting operations by simply loosening thumbnut 30 b, flipping blade 34 over, and re-tightening thumbnut 30 b.
Illustrated in FIG. 8 the blade holder 1 has two smooth guiding surfaces 32 a and 32 b which are parallel with slots 20 . This parallel orientation of the slots 20 and the guiding surfaces 32 a and 32 b allows the blade 34 to be maintained at a predetermined precise distance D from surface 40 a of structure 40 . This distance remains constant even when the holder is slid about the surface 40 a of structure 40 .
FIG. 9 shows that the receptacle slots 20 are arranged in a stacked configuration and evenly spaced at relatively small increments to facilitate a high degree of distance adjustability d 1 -dn between the blade 34 (not shown) and the guiding surfaces 32 a and 32 b.
As can be demonstrated in FIG. 10A the purposefully designed exposure of the entire sharp edge 34 b of blade 34 allows the user to skillfully manipulate the depth that the blade 34 penetrates sheet material 44 . This on the fly adjustability allows the user to utilize the entire sharp edge 34 b of blade 34 while performing a cutting operation enabling the use of a sharper less used portion of blade edge 34 b if difficulties due to dulling of a particular area of blade edge 34 b are encountered during a cutting operation.
Another feature demonstrated in FIG. 10B is how the purposefully designed rounded receptacle end 14 of blade holder 1 along with the exposure of the entire sharp edge 34 b of blade 34 allows the user to greatly vary the angle of attack of blade 34 . without interference that would be encountered with a square ended trimmer. when severing sheet material 44 . This feature is especially important when structure surface 40 a is short or shallow. as shown in FIG. 10B, allowing only the small end portion of guiding surface 32 a or 32 b to be utilized during a cutting operation. This ability to vary the angle of attack of blade 34 also allows the user to precisely trim into corners and around obstacles in circumstances such as illustrated in FIG. 10 B.
In both circumstances illustrated in FIGS. 10A and 10B, the ability to utilize the entire sharp edge 34 b greatly increases the usable life of blade 34 , compared to trimmer tools that only utilize the sharp point 34 c of blade 34 , which dulls very quickly.
Shown in FIG. 11 the blade holder 1 is being used to sever sheet material 44 at a precise predetermined overlap distance D from the outside intersection 41 of two surfaces 40 a and 40 b of structure 40 . Blade holder 1 is slidingly guided along surface 40 a of structure 40 trimming sheet material 44 which extends from surface 40 b past the line of intersection 41 extending relatively perpendicular in relation to surface 40 a, guiding surfaces 32 a and 32 b , and cutting plane of blade 34 . Once trimmed, the sheet material 44 can be finally applied to surface 40 a to provide an aesthetic and functional uniform line of overlap.
Shown in FIG. 12 the blade holder 1 is being used to sever sheet material 44 at a predetermined distance D from the inside intersection 42 of two surfaces 40 c and 40 d of structure 40 . This is achieved by slidingly guiding the blade holder 1 using one of the guiding surfaces 32 a or 32 b along structure surface 40 c allowing tip 34 c of blade 34 to pierce and sever sheet material 44 taking care not to penetrate too deeply into structure surface 40 d . Once trimmed, the sheet material 44 can be finally applied to surface 40 d to provide an aesthetic and functional uniform line of overlap.
A similar cutting operation is depicted in FIG. 13 where blade holder 1 can be slidingly guided tangentially on curved or rounded corner of structure 40 , trimming sheet material 44 at a precise predetermined distance D of overlap. Once trimmed, the sheet material 44 can be finally applied to corner 40 c to provide an aesthetic and functional uniform line of overlap.
Some other cutting operations are illustrated in FIGS. 14-16. Pin-striping can be cut from sheet material 44 with blade holder 1 in any number of ways by selectively configuring blades 34 to cut the desired width and number of stripes 50 . By using a suitable cutting surface 48 , these stripes 50 can be made linear such as with a straightedge 46 , or as shown in FIG. 15, more organic freehand curves 52 . This multiple blade configuration could also be used, with or without the use of a template (not shown), to cut designs, letters, numbers or shapes 54 , for example, from sheet material 44 with a uniform width or border as illustrated in FIG. 16 .
Blade holder 1 can also be used simply to hold a single blade 34 , as shown in FIG. 1, to perform any variety of cutting tasks.
Although the preferred embodiment of the present invention has been explained in detail, hereinabove, the present invention should not be limited to this embodiment alone, but various modifications and changes can be made thereto without departing from the scope of the invention defined in the appended claims.
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A multiple receptacle blade holder tool including an elongated rectangular cross section main body with one end being rounded and having multiple rectangular receptacles for blades. The blade holder also has top and bottom surfaces parallel to the blade receptacles and a relief channel forming independent legs that clamp one or more blades in the holder.
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[0001] This application claims priority to U.S. provisional application No. 60/815,836, filed on Jun. 23, 2006, which is hereby incorporated by references in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates generally to the field of geocoding and more particularly to a method and apparatus for geocoding with improved positional accuracy.
BACKGROUND OF THE INVENTION
[0003] Geocoding involves programmatically assigning x and y coordinates (usually but not limited to, earth coordinates—i.e., latitude and longitude) to records, lists and files containing location information (full addresses, partial addresses, zip codes, census FIPS codes, etc.) for cartographic or any other form of spatial analysis or reference. Geocoding is even more broadly described as “mapping your data” in order to visualize information and explore relationships previously unavailable in strict database or spreadsheet analysis.
[0004] A centroid is a geographic center of an entire area, region, boundary, etc. for which the specific geographic area covers.
[0005] Street vectors are address segments of individual streets, which may contain attributes such as address ranges. Street vectors are used in displays of digitized computer-based street maps. Range information on street vectors is typically specified on the left and right side of each vector. They are also used for geocoding a particular address to a particular street segment based on its point along the line segment.
[0006] Geocoding is currently performed by running non-geocoded (referred to hereafter as “raw data”) information such as a list of customers through proprietary software and/or data, which performs table lookup, fuzzy logic and address matching against an entire “library” of all known or available address points or street vectors (referred to hereafter as a “georeferenced library”) with associated x, y location coordinates. If the raw data matches a point record from the georeferenced library, then the raw data is assigned the same x, y coordinates associated with the matching record from the georeferenced library. If the raw data instead matches a street vector, then the raw data is assigned interpolated x,y coordinates pair based on the x,y coordinates of the high and low address for the matched street vector in the georeferenced library.
[0007] The georeferenced library is compiled from a number of varied sources, depending on the territory, including census information, postal address information, street vectors with associated address ranges, postcode centroids and other various sources of data containing geographic information and/or location geometry. If a raw data address cannot be matched exactly to a specific library street address (known as a “street level hit”), then an attempt is made to match the raw data address to an ever decreasing precision geographic hierarchy of point, line or region geography until a predetermined tolerance for an acceptable match is met. The geographic hierarchy to which a raw data record is finally assigned is also known as the “geocoding precision.” Geocoding precision tells how closely the location assigned by the geocoding software matches the true location of the raw data.
[0008] FIG. 1 illustrates a street segment called Main Street. The illustrated Main Street segment is for the odd side of Main Street and has an address range of 1 to 99 (odd numbers only) spanning between segment endpoints A and B. The coordinates of endpoint A are (X,Y) while the coordinates of endpoint B are (X 1 , Y 1 ). Heretofore, interpolation of input addresses in a geocoder was accomplished by considering the available high and low address range data in a georeferenced library for the given street segment and calculating where on that segment an input address from the raw data ought to reside based upon the latitude/longitude pairs of those two endpoints.
[0009] For example, as illustrated in FIG. 1 , given the Main Street segment, current interpolation methods will assume that addresses exist at points equidistant from each other and that the determination of where an input address from the raw data resides on a given segment is calculated using the coordinates of the segment endpoints A, B (or nodes) from the georeferenced library. Current interpolation will place an input address of 33 Main Street approximately one third (point C) of the way along the segment.
[0010] The disadvantage of the prior art methods is that they fail to consider that houses, buildings, etc. are typically not located at regular intervals along a street vector or sometimes do not utilize the full range of possible address numbers assigned by the postal authority for the street vector. As such, these methods are not as accurate as they should be, which is undesirable. Users of such geocoding methods may assign locations to addresses on a street vector that are incorrect when compared to the actual ground truth positions of addresses on that street vector. For example, traditional interpolation can result in clustering addresses in close proximity at one end of a street vector when the actual addresses are distributed along a greater length of the street vector. In FIG. 6A , the pushpins on the image depict the results of using a traditional interpolation technique to geocode addresses 2, 14 and 22 on Bieniek Ave, Adams, Ma., for which the postal authority has assigned the possible addresses of 1 through 99. In reality, the even-numbered addresses on the full length of the street, as indicated by the numbered stars, range only up to 22. Traditional interpolation methods assume the existence of addresses 2 through 98 on the even side of the street and therefore locate 2, 14 and 22 as being clustered on one end of the street, which in this instance is incorrect. Thus, use of the existing geocoding methods can result in errors in analysis and/or logistics where location is a key component. Accordingly, there is a desire and need for more accurate geocoding technique.
BRIEF SUMMARY OF THE INVENTION
[0011] Embodiments of the invention provide a method and apparatus that improves the positional accuracy of a geocoded point in comparison to traditional goecoding methods and geocoders. The method and apparatus disclosed herein utilize externally generated ground truth data (when available) in conjunction with address range information for a given segment (e.g., street segment) to achieve positional accuracy not currently obtainable in the prior art. The additional data is searched for and included in the interpolation methodology in a dynamic manner and in real time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates interpolation of an address within a street segment according to conventional geocoding methods.
[0013] FIG. 2 illustrates interpolation of an address within a street segment according to an embodiment of the invention.
[0014] FIG. 3 illustrates a further interpolation of an address within a street segment according to an embodiment of the invention.
[0015] FIG. 4 is a flowchart of a geocoding method of the invention.
[0016] FIG. 5 illustrates a geocoder constructed in accordance with an embodiment of the invention.
[0017] FIGS. 6A and 6B illustrate the difference between interpolation results with prior art and interpolation with the current invention for addresses on a street segment in Adams, Ma.
DETAILED DESCRIPTION OF THE INVENTION
[0018] As set forth above, prior art geocoding methods fail to consider that houses, buildings, etc. are typically not constructed equidistant from each other. Nor do they consider the advent of point data files that are now becoming more available such as for example, point data via parcel centroid data or addresses located via GPS devices. To use this ground truth data optimally, a geocoder must be equipped to consume this additional data in a dynamic fashion, during run-time of the geocoding process, without requiring incremental modification of an underlying georeferenced address dictionary. To date, this has not been done.
[0019] U.S. Pat. No. 6,101,496, assigned to MapInfo Corporation and incorporated herein by reference, considered the incorporation of different sources of street and/or address point information in the pre-processing of a native address dictionary upon which input addresses are geocoded. The '496 patent, however, does not disclose or suggest a dynamic ability to consume and consider additional address information to pin point a location within a segment.
[0020] The embodiments of the invention, on the other hand, allow users to introduce/input point data at any time. The point data, which is external to the native address dictionary, will be considered dynamically at run-time when input addresses are being assigned latitude/longitude coordinates during the interpolation process. This capability removes the need of the software vendor to extend the pre-generated georeferenced dictionary via additional processing. As such, the embodiments of the invention solve a long-felt need by allowing users to independently improve the quality of the geocoding process through their own efforts.
[0021] FIG. 2 further illustrates the FIG. 1 Main Street segment as interpolated in accordance with an embodiment of the invention. The illustrated Main Street segment is for the odd side of Main Street and has an address range of 1 to 99 (odd numbers only) spanning between segment endpoints A and B. The coordinates of endpoint A are (X,Y) while the coordinates of endpoint B are (X 1 , Y 1 ). Using the example above, a geocoder that can recognize and consider point data (such as e.g., parcel centroids or GPS-generated point files) within e.g., a pre-defined address dictionary, user dictionary or from any other external source, can improve upon the traditional interpolation method and generate a more accurate set of coordinates for the input address.
[0022] Modifying the example described above, it is now assumed that the location of 17 Main Street is known (point D). The information regarding 17 Main Street may be housed in a pre-defined address dictionary, user-generated input dictionary, or it may be dynamically retrieved from another location (e.g., over the Internet or other connection to an external database). When the user requests the geocoder to locate the position of 33 Main Street, the geocoder of the invention determines a different set of coordinates from the prior art geocoder by interpolating between the closest known point with a house number less than 33 (which is 17 or point D) and the known point with a house number greater than 33 (which in this example is the endpoint B having address 99). Accordingly, as can be seen by comparing FIG. 2 to FIG. 1 , the positional accuracy for locating 33 Main Street (point C′) has greatly improved.
[0023] FIG. 3 illustrates the results of the interpolation performed in accordance with the invention when an additional point E, having e.g., address 43 Main Street, is available in the pre-defined georeferenced dictionary or from any other external source. As illustrated in FIG. 3 , the proposed interpolation can further refine the location of 33 Main Street by calculating the distance between 17 (point D) and 43 (point E) Main Street and determining where 33 Main Street (point C″) is most likely situated.
[0024] FIG. 4 illustrates a method 100 according to an embodiment of the invention. FIG. 5 illustrates an example embodiment of a geocoder 200 of the invention. The geocoder 200 comprises a computer or processor 202 having geocoding software capable of interpolating data from a variety of data sources and running the method 100 of FIG. 4 . The sources illustrated in FIG. 5 include a georeferenced address dictionary 206 , a user-supplied point data dictionary/database 208 and web-based sources of address point data 204 . The web-based sources of address point data 204 can include sources such as the Ordnance Survey in the United Kingdom, the Public Sector Mapping Agencies in Australia, or proprietary data warehouses developed and maintained by organizations and accessible only within those organizations. An example of the latter could be a utility company that establishes locations for its physical assets via GPS units. It should be appreciated that any source of address point data may be utilized and the invention is not to be limited to those illustrated in FIG. 5 . The web-based and user supplied point data dictionaries/database 204 , 208 will contain known data points and associated address information and coordinates for each data point.
[0025] The method 100 begins by inputting an address to be geocoded (hereinafter the “input address”) at step 102 . At step 104 , the method 100 determines if a street vector match was found in the georeferenced address dictionary 206 . If a match was not found, the input address is compared to non-georeferenced postal data at step 114 and the method 100 completes. The result is the derivation of a latitude/longitude coordinate pair based upon a typically less geographically precise centroid rather than an interpolated street level “hit.” If at step 104 , it was determined that there was a street vector match, the method 100 continues at step 106 and captures the address ranges and associated coordinates from the matched street vector. At step 108 , a search is made for external point data associated with the matched street vector. The search includes querying the web-based and user-supplied sources of point data 204 , 208 .
[0026] At step 110 , the method 100 determines if external point data has been found. If external point data has not been found, the method 100 interpolates coordinates of the input address based on the address range coordinates associated with the matched street vector (step 116 ). If at step 110 , it was determined that there is external point data, the method 100 continues at step 112 , where the method 100 interpolates coordinates of the input address based upon the address range coordinates associated with the matched street vector and the externally discovered point locations. In a preferred embodiment, interpolation is performed by interpolating between the closest known point with an address less than the input address and the known point with an address greater than the input address (see e.g., the description regarding FIGS. 2 and 3 above). After steps 112 and 116 , the method 100 terminates.
[0027] It should be appreciated that the method 100 is implemented in software and may be stored on a computer readable storage medium such as a hard disk drive, floppy disk, CD-ROM, DVD and sold as an article of manufacture. The computer instructions implementing method 100 may also be stored on a network server and subsequently downloaded over a network to a computer system or other device/system. The computer instructions implementing the method 100 may also be programmed into various read only memory chips within or attached to the computer 202 , if desired.
[0028] As described above, by using intermediate points on a street segment, input from a pre-defined geo-referenced address dictionary, user dictionary, or from other external sources, as opposed to solely considering the known endpoints of a given segment, the invention's interpolation of the derived location of an input address is a more accurate geographic representation of that address than other methods known in the art because it considers intermediate points whose ground truth is known and accepted as valid. This is evident by comparing the interpolation result shown in FIG. 6A (traditional) with the result illustrated in FIG. 6B . The pushpins in FIG. 6B illustrate the vastly improved geocoded locations of the same addresses shown in FIG. 6A , the improvement results from the method 100 performed in accordance with the invention. In addition, by including the availability of externally-sourced address point data, the embodiments of the invention further enable the interpolation methodology to be implemented in a dynamic fashion, consuming user-provided data as it is introduced at any time in the life cycle of the geocoding software. That is, the end result of the invention's geocoding process is an interpolated point that better approximates the ground truth position of the input address based on the combination of known endpoints for the matched street segment as well as the known location of other addresses associated with that segment.
[0029] While the embodiments of the invention have been described in detail in connection with preferred embodiments known at the time, it should be readily understood that they are not so limited. Rather, the embodiments can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Accordingly, the embodiments of the invention are not limited by the foregoing description or drawings, but are only limited by the scope of the appended claims.
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A method and apparatus that improves the positional accuracy of a geocoded point in comparison to traditional goecoding methods and geocoders. The method and apparatus utilize ground truth data (when available) in conjunction with address range information for a given segment to achieve positional accuracy not currently achievable in the prior art.
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FIELD OF THE INVENTION
The present invention relates to a method and apparatus for recovering fiber useful for paper making from mill effluent streams containing fiber and substantial quantities of contrary materials.
BACKGROUND OF THE INVENTION
In a secondary fiber papermaking mill, paper, such as tissue, is made from secondary fiber furnishes, such as recycled office paper, newspaper, and magazines, obtained in municipal curbside paper collections and business paper waste collection, for example. Papermaking fibers are extracted from the waste paper sources and supplied to a conventional papermaking machine. Since the source of the papermaking fibers is waste paper, other materials not useful for papermaking are also usually present. These contrary materials, and the water in which the source materials are carried, must be processed efficiently and handled and disposed of in an environmentally responsible manner.
The use of secondary fiber furnishes continues to increase in the manufacture of pulp and paper. The economic feasibility of using such secondary furnishes depends on the fraction of useful fiber that can be extracted from the total furnish. The size of this useful fiber fraction, known as the yield, depends in large part on the type of waste paper that makes up the furnish. Secondary furnishes, as mentioned, contain substantial amounts of materials not useful for making paper, called contrary materials, for example, fiber fines, staples, paper clips, inks, clays, and the like. While the theoretical yield of a furnish can be determined with precision, perfect recovery of the theoretical yield has yet to be achieved because of technological deficiencies in the recovery processes in current use, or other difficulties.
Conventional processes, as a result of such deficiencies, reject useful fiber that is then lost to disposal. The actual yield of such conventional processes may be increased by the recovery of this fiber.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for recovering useful fiber from effluents which contain substantial quantities of contrary materials. The present invention, generally, provides a method and apparatus that overcomes the deficiencies in the art and recovers fiber useful for paper making from effluent at a higher yield than conventional fiber recovery methods.
More particularly, the present invention provides a primary process, utilizing well defined unit operations, for recovering usable papermaking long fiber from mill effluent. Unlike other methods, the method according to the present invention does not add additional water to the effluent stream for processing, which results in less water usage and less water that must be later cleaned, advantageously saving both resources and expense.
The solid concentrations in effluent streams are typically quite low, usually in the range of 0.1% to 0.5% consistency. Contrary materials in effluent streams consist of a variety of materials, including: suspended solids, such as kaolin clay, cellulose fines, lignins, starches and tannins; large scraps of wood, plastic sheet, and fiber bundles; staples, paper clips, sand and glass shards; coating flakes, stickies and styrofoam and similar materials; fine coating specks; and inks. The process according to the invention includes steps to process contrary material according to size and type that maximizes the recovery of useful fiber. In addition, the separation techniques simplify handling of the contrary materials, which are separated into three categories, suspended solids and ink, coating flakes, and inorganic solids. The method also separates the contrary materials in a manner that recovers water for re-use in the fiber de-inking process.
A primary process for recovering paper making fibers from an effluent stream in accordance with the invention comprises steps for separating useful material from reject material that minimizes loss of useful fiber. The method of the invention includes the steps of:
(a) collecting fiber containing effluent in a collection basin;
(b) directing the effluent from the collection basin through a bar grate to separate solid scrap materials from the fiber containing effluent;
(c) screening the fiber containing material through a coarse barrier screen to remove solid materials from the accept effluent;
(d) extracting long fibers from the fiber containing effluent in a curved wire washer, rotating drum, or disk filters;
(e) cleaning the extracted long fibers in a high consistency centrifugal cleaner to remove solids having a specific gravity greater than long fibers;
(f) dilution and further cleaning the accepted material from the high consistency centrifugal cleaner in a low consistency forward centrifugal cleaner to separate fine solids having a specific gravity greater than long fibers;
(g) screening accept material of the forward centrifugal cleaner through a fine barrier screen; and
(h) flotation de-inking of the accept material of the fine barrier screen.
An apparatus according to the present invention performs the steps of the method.
An additional aspect of the invention is the inclusion of secondary processes for the recovery of useful fiber from material reject in the primary process. Secondary process operations that act in parallel with the primary process capture long fibers rejected in the primary process and return the captured long fibers to the primary process for recovery, thereby increasing the net fiber yield of the overall method.
The secondary process operations according to the invention also separate the contrary materials for simplified handling and disposal. The secondary process operations separate the contrary materials into three categories suited for different handling operations, suspended solids and inks, coating flakes, and inorganic solids. Suspended solids may be clarified to yield water for recycling and a solid material suitable for producing granular industrial absorbents and other useful products. Coating flakes may be used as fuel in a waste recovery boiler. The inorganic solids, such as staples, sand and glass shards, are usually disposed of in landfills. The smaller quantity of landfill disposed materials reduces the pressure on the environment and the cost of handling and disposing of solid wastes.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The present invention can be further understood with reference to the following description in conjunction with the appended drawing. The drawing is a schematic representation of the method and apparatus of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In accordance with a preferred embodiment of the invention, the drawing shows a primary process for the recovery of long fibers from an effluent stream, indicated by the steps appearing in the upper row of the figure. The term "long fibers" refers to cellulose fibers that have sufficient length to be retained in the Fourdrinier wires of a paper-making machine. Typically, long fibers have a length greater than 1 mm (0.04 inches). The primary process is supplemented by a secondary process that increases the yield of the primary process, indicated by the steps appearing in the lower row. The primary process is designed to recover about 80% of the long fibers useful for papermaking, while rejecting about 95% of the contrary materials. The secondary process is designed to recover about 80% of the long fibers that are rejected in the primary process. About 90% of the contrary material entering the secondary process are rejected for disposal or sent to effluent clarification with the suspended solids.
Mill effluents usually consist of several streams from the various processes in the de-inking and papermaking process. The various streams are directed into a collection basin 10 or pit by gravity flow. All waste streams of potential fiber recovery sources, particularly floor drains, may be collected, and no source is left open for discharge to an industrial sewer or to an effluent treatment facility producing sludge for disposal. By collecting the streams in a collection basin 10, the effect of fluctuations in flow rate of the various streams is reduced. The collection basin 10 also accommodates surges caused by dumped stock or white water chests. Materials recovered from the secondary recovery processes are also collected in the collection basin 10 for reprocessing in the primary process. It has been found advantageous to provide a collection basin 10 sufficiently large so that effluent has a residence time of 10 to 15 minutes at the observed nominal flow rate.
The primary process takes effluent slurry from the collection basin 10 and separates usable long fibers from the contraries and returns the usable fibers to the papermaking process. Each step of the primary process separates a particular type or size contrary from the slurry, and passes the accept material, that is, the long fiber and unseparated contraries, to a further step. The reject material is further concentrated and classified in the secondary process operations, as described below.
In the primary process, effluent is discharged from the collection basin 10 to a channel 12 and through a bar grate 14 to screen out large segments of contrary materials, for example wood and plastic scraps. According to a preferred embodiment of the invention, the bar grate 14 may consist of a device interposed in the flow channel 12 having 21/2 inch deep bars spaced apart 1 or 2 inches to form a coarse vertical barrier. A rake device with tines positioned between the bars pulls the trapped material upward to keep the face of the bar grate 14 clear. This material is discharged through chute 13, and ultimately disposed of in a waste recovery boiler. A device found to be suitable is the Climber Screen by Infilco Degremont.
Effluent that has passed through the bar grate 14 is pumped through a pipe 16 to a coarse barrier screen 18 which removes smaller contraries, such as coating flakes, stickies, styrofoam particles and coarse sand and glass shards. The coarse barrier screen preferably comprises a screen basket having openings in the range of 0.050 to 0.062 inches. The device includes a rotating element that generates pressure pulses to prevent fibers from blinding the screen. A device found to be suitable is the Centriscreen® manufactured originally by the Bird Machine Co.
A stock chest, or basin, and pump 15 may be provided to collect the effluent from the bar grate 14 and pump it to the coarse barrier screen 18. The illustrated embodiment of the invention shows locations where stock chest and pump units 15 may be advantageously installed.
Effluent passing through the coarse barrier screen 18 is pressured through a pipe 20 to the extraction unit 22, which separates suspended solids, such as kaolin clay, cellulose fines, lignins, starches and tannins from the effluent. The extraction unit 22 preferably comprises a curved wire screen formed from a plurality of parallel wedge wires shaped in a 120 degree arc and spaced apart about 0.004 to 0.012 inches (100 to 300 microns) to form a collecting surface for the fibers. The effluent stream is directed tangentially against the top of the screen. Suspended solids carried by water pass through the slots, and are directed through a pipe 44 to effluent clarification. Fiber is retained on the surface formed by the wires. Such a device separates about 85 to 90% of the water and suspended solids from the effluent. The Micrasieve by C-E Bauer has been found to be suitable for use as the extractor. Other devices suitable for use include rotary drum washers and disk filters. The accepted stock consistency is typically between 2% and 4%.
The long fibers collected by the extraction unit 22 are pumped through a pipe 24 to a centrifugal cleaning device 26 to remove relatively high specific gravity contraries, such as staples, sand, grit and glass, from the fiber. In a preferred embodiment of the invention, a high consistency centrifugal cleaner, for example, the Liquid Cyclone from Black Clawson Co., is suitable as the centrifugal cleaning device.
Cleaned fiber from the centrifugal cleaning device 26 is then pressured through a pipe 28 to a low consistency forward centrifugal cleaner 30, to remove small grit and similar material not removed in the high consistency centrifugal cleaner 26. A suitable device for the forward centrifugal cleaner 22 is the RB 90 manufactured by Ahlstrom, having a 3 to 4 inch diameter cone. The Centri-Cleaner® from C-E Bauer has also been found to be suitable.
Preferably, the forward centrifugal cleaner may comprise a bank of cleaners in series. In the illustrated embodiment, reject from the forward centrifugal cleaner 30 is sent through a pipe 50 to a secondary forward centrifugal cleaner 31. The secondary forward centrifugal cleaner 31 is similar to the forward centrifugal cleaner 30, and removes very fine, high density particles, such as glass fragments, from the material. Additional forward centrifugal cleaner stages may be provided to minimize fiber loss by additional reprocessing of the reject material. Accept material is fed from the secondary forward centrifugal cleaner 31 through a pipe 48 to the primary process immediately upstream of the forward centrifugal cleaner 30 for reprocessing. Reject material is discharged through a chute 62 for landfill disposal.
Accept material from the forward centrifugal cleaner 30 is pressured through a pipe 32 through a fine barrier screen 34, which removes very small contrary materials, for example, fine specks and stickies, from the fiber. According to a preferred embodiment, the fine barrier screen 34 includes a screen basket provided with slot shaped openings in the range of 0.004 to 0.006 inches. The long papermaking fibers pass through the screen plate. A rotating element sweeps the screen surface with pressure pulses to prevent fibers from blinding the screen surface. The fine barrier screen 34 is most efficiently operated with an effluent at about 1.3% consistency. A fine barrier screen 34 of the type contemplated here is the LaMort Fiberprep SPM Series pressure screen.
Accept material from the fine barrier screen 34 is pressured through a pipe 36 into a flotation de-inking module 38. The de-inking module 38 removes fine particles of ink and coating materials from the fiber. In the flotation de-inking module 38, an air diffuser inducts and mixes air into the fiber slurry. The fine contrary particles, ranging in size from about 50 to 150 microns, are then removed from the surface of the slurry as a froth. The flotation de-inking module 38 operates most efficiently with an effluent at about 0.7% to 1.3% consistency. The CF Flotation Cell series originally manufactured by Escher Wyss has been found to be a suitable de-inking module.
The de-inking operation completes the primary fiber recovery process. Material recovered from the de-inking module is returned through a pipe 40 to the main fiber preparation process of the plant for use in papermaking. The fiber recovered by the method according to the invention is typically sufficiently clean to be introduced well downstream in the fiber preparation process. Pulping, de-trashing and coarse cleaning operations are not usually necessary.
The secondary process operations recover usable fibers rejected in the primary process and recycle the fibers to the collection basin 10 or the extraction unit 22 for recovery in the primary process. The various components in the secondary process generally may be smaller in size and/or capacity than the corresponding units in the primary process because of the lower flow quantity in the secondary process. Reject material from the secondary process is separated mainly into organic and inorganic fractions, concentrated and discharged for disposal or sent to effluent clarification.
Reject material from the coarse barrier screen 18, which, as mentioned, consists of relatively large contraries, is pumped through a pipe 42 to a secondary high consistency centrifugal cleaner 72, which is preferably a unit similar to the high consistency centrifugal cleaner 26. The secondary high consistency centrifugal cleaner 72 removes grit-like material from the reject material of the coarse barrier screen 18.
Rejected grit is discharged by gravity through chute 70 to a grit removal screw 64, which separates grit solids from water. In addition, grit removed by the high consistency centrifugal cleaner 26 is discharged through a chute 46 to the grit removal screw 64. The grit screw 64 separates grit from water, and the grit is discharged through a chute 66 for disposal, preferably to a landfill. Water from the grit removal screw 64 is returned to the collection basin 10 through a pipe 68 by gravity discharge. The Sand Separator manufactured by Con Silium Bulk-Babcok has been found to be a suitable grit removal screw.
The accept material from the secondary high consistency centrifugal cleaner 72 is pressured through a pipe 74 to a secondary coarse barrier screen, a unit similar to the coarse barrier screen 18 of the primary process. Accept material from the secondary coarse barrier screen is recycled through a pipe 78 to the collection basin 10 for reprocessing in the primary process. Reject material is pressured through a pipe 80 to the tertiary coarse barrier screen 82 for further separation. The tertiary coarse barrier screen 82 preferably comprises a horizontal cylinder having perforations in the range of 0.080 to 0.120 inches in diameter. The concentration of relatively large sized contraries in this reject material requires the larger hole sizes. The screen 82 is kept clean by a rotating element in conjunction with a low pressure water shower. The Reject Sorter originally manufactured by Bird Escher Wyss is a suitable unit for use as the tertiary coarse barrier screen 82. Accept material is returned through a pipe 86 to the collection basin 10 by gravity flow. Reject material from this step, which typically has a consistency of 30% to 50%, is sent for disposal through a chute 84, preferably to an on-site waste recovery boiler.
Reject material from the fine barrier screen 34 is pumped through line 52 to a secondary fine barrier screen 56, which is similar in design and operation to the fine barrier screen 34 in the primary process. Accept materials are pressured through a pipe 54 to the extraction unit 22. Reject material is discharged through a pipe 58 for effluent clarification. Clarified water is suitable for recycling to the fiber preparation area of the mill. The concentrated solids removed by effluent clarification may be further densified, granulated and dried for use as industrial absorbents or agricultural carriers.
The foregoing has described the preferred principles, embodiments and modes of operation of the present invention; however, the invention should not be construed as limited to the particular embodiments discussed. Instead, the above-described embodiments should be regarded as illustrative rather than restrictive, and it should be appreciated that variations, changes and equivalents may be made by others without departing from the scope of the present invention as defined by the following claims.
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A method for recovering fiber useful for papermaking from an effluent stream includes a primary process for treating an effluent stream to separate usable fiber from contrary matter, and secondary operations, supplementing the primary process, to treat the contrary matter rejected by the primary process to recover usable fibers contained in the reject matter. In addition, the secondary processing steps separate the reject material into organic and inorganic fractions, which may be usable in other processes. The method of the invention does not require the addition of water as do conventional processes, simplifies handling, disposal, and reduces the costs of disposal.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The invention relates to a process and an installation for anaerobic degradation of waste containing organic solids, in the form of a paste having a high solid concentration, in any case higher than 15%, and in particular ranging between 25% and 30%.
The present invention relates more particularly to the field of the anaerobic degradation of waste formed of heterogeneous organic solids which can contain undesirable particles, in particular heavy and non-organic particles, likely to settle in a fermentation tank, such as for example stones, glass or metal compounds.
(2) Description of the Prior Art
Solid organic waste the degradation of which is the objective of the present invention is previously prepared in the form of a paste with high solid concentration, whereby said paste may be fibrous, but in any case compact.
In the field of the anaerobic degradation of effluents with low solid content, which are hence more liquid than pasty, are known processes for anaerobic degradation using adapted tanks.
FR 2 510 605 for example discloses a process and an installation for degradation in wet anaerobic medium of organic products, by-products and waste, comprising a reactor having a cylindrical fermentation tank vertically divided into two parts by a central partition. The first part is connected by a siphon to a supply well and the second part is connected by a siphon to a discharge well for the material. The supply and the discharge of the products occur through pneumatic thrust.
FR 2 530 659 takes this same structure and proposes to improve it by submitting the effluents to a direction of tormented circulation inside the tank, while providing biogas injection through short and successive jets through conduits ending onto the bottom of the tank.
According to an embodiment of the tank described in these documents, the supply and discharge wells are located in the vicinity of each other, the above mentioned partition being arranged vertically between the two openings of said well ending into the reactor. This partition has a width smaller than the width of the tank and a height smaller than the height of the tank, the bottom of the tank having a double slope having substantially the shape of an ellipse.
According to another embodiment of the tank also described in these documents, the above-mentioned supply and discharge wells are substantially diametrically opposite each other, the vertical partition separating the fermentation tank substantially diametrically, with a height smaller than the height of the tank and leaving communicating passages between the two compartments in the upper and lower portions in order to favour an upward movement of the material in the first portion and a downward movement in the second portion, the bottom of the tank having one single slope.
Even more specifically, FR 2 551 457 proposes to subdivide the enclosure into a plurality of sectors through intermittent injection of biogas, taken from an appropriate storage tank, into each one of said sectors under a predetermined pressure and time period. The biogas is re-injected into each sector successively, i.e. shifted in time, so as to achieve a rotation of the biogas injection into the enclosure, from one sector to the next one.
Finally, FR 2 577 940 proposes to remove the material-supply and discharge wells in order to reduce the construction costs. In this case the products to be degraded are injected directly into the enclosure, preferably towards the bottom of said enclosure, and the exit of the degraded products occurs by gravity. The mechanical thrust is carried out by a pump for thick material, preferably with piston or screw.
One of the disadvantages of the prior known solutions lies in the complexity of the digesters resulting from same. In particular, the manufacture of these digesters is expensive, because of the constraints of internal partitioning and the specific designs of the means for supplying and discharging effluents.
Indeed, when such digesters are used with a paste having a high solid concentration, the partitions carried out must have high mechanical strength because of the pressures exerted by the thick paste in movement. This results into high manufacturing costs.
In fact, the manufacturing constraints on the state-of-the-art digesters increase according to the increase of the size of the tank of the digester.
It also appears from this statement of the state of the art that one of the problems not perfectly solved by the existing processes and digesting devices is the control of a homogeneous circulation of the material to be digested between the supply and discharge paths.
The circulation of the material in the form of effluents occurred so far through partitioning and a tormented control of the flow of effluents inside said tank.
SUMMARY OF THE INVENTION
The present invention pretends to cope with these disadvantages of the state of the art through a finally very simple process and installation.
To this end, the invention relates to an process for anaerobic treatment of material with a high solid concentration, i.e. higher than 15%, in a digester in the form of a closed tank provided with means for supplying material to be treated and means for discharging the digested material as well as means for vertical homogenisation in the form of gaseous-fluid injectors on the bottom of the tank, wherein, through a distribution at the level of the tank of the means for supplying material with respect to the discharge means and through the means for vertical homogenisation guaranteeing the homogeneity of the material by vertical sectors in the tank, a uniform forced unidirectional circulation is imparted to the material in the tank over the full cross-section of the latter, and according to a substantially horizontal component, between said supply means and said discharge means.
Advantageously, the internal space of said tank is cut into vertical sectors by the arrangement of the homogenisation means and the vertical sectors are homogenized intermittently and successively by the homogenisation means.
A preferred extraction of the settled particles in the lower portion of the tank and/or a recirculation of the material between the discharge means and the supply means can also be performed.
According to another feature, this recirculation can occur during short periods of time.
The invention also relates to an installation for implementing the process, comprising a digester in the form of a closed tank provided with means for supplying material to be treated and means for discharging the digested material as well as means for vertical homogenisation in the form of gaseous-fluid injectors on the bottom of the tank, wherein the means for supplying material are arranged at the level of the tank diametrically opposite the means for discharging the digested material, and, in combination, the means for vertical homogenisation are comprised of gaseous-fluid injection ramps extending in the bottom of the tank transversely to the substantially horizontal direction of flow of material in the tank.
According to another feature, the means for supplying material and the means for discharging the digested material are arranged to an arc of a circle on the circular cross-section of the tank. They can also be arranged at different heights of the tank.
The gaseous-fluid injectors are advantageously arranged on slopes parallel to each other and perpendicular to the direction of advancing of the material in the tank.
The installation can also comprise a device for discharging the digested material, in particular a device allowing their additional dehydration.
According to another feature, the installation can in addition comprise a circuit for re-circulating the material between the discharge means and the supply means.
The invention thus permits to treat under favourable conditions, by digestion, heterogeneous organic solids, for example domestic and comparable waste (urban, industrial, agricultural waste, etc), having a high solid content, for example about 25% to 30%.
Thanks to the present invention the construction of the installation will be simplified and the manufacturing cost will be radically reduced. Furthermore, a broader range of material will be usable for said construction.
Other objectives and advantages of this invention will become clear from the following description. The understanding of this description will be facilitated when referring to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic and elevation view of a tank according to a first variant of embodiment,
FIG. 2 is a schematic view of the cross-section of a tank forming a digester according to the installation of the invention,
FIG. 3 is a schematic view representation of the gaseous-fluid injecting ramps extending on the bottom of a tank,
FIG. 4 is a schematic and elevation view of a tank according to a second variant of embodiment,
FIG. 5 is a view of a particular arrangement of a gaseous-fluid injector at the level of a material-discharge opening located in the lower portion of a tank,
FIG. 6 is a schematic and elevation view of a tank provided with means for accelerating the material in the tank.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As can be seen in the figures of the attached drawings, the present invention relates to a process and an installation for anaerobic treatment of waste having a high solid concentration. In this connection, it should be noted that the invention specifically relates to the treatment of such waste containing organic solids, in the form of a paste having a high solid concentration, in any case higher than 15%, and in particular ranging between 25% and 30%, and thus comprised of material having a low water content.
The solid organic waste the degradation of which is the objective of the present invention is previously prepared, in particular by the addition of a liquid, for example water resulting from the dehydration of the digested material, in the form of a paste with a high solid concentration, whereby said paste can be fibrous, but in any case compact.
This waste can in addition, without this being systematic, contain non-organic heavy particles likely to settle in a fermentation tank.
Its high solid concentration provides the paste to be treated within the framework of the invention with such a viscosity that the settling phenomena, even if they exist, are limited.
Since the material used is in the form of a paste, the terms “material” and “paste” will thus indifferently be used generically to denote all this material likely to be treated by means of the present invention.
According to the process of the invention, the anaerobic degradation of organic solids with a high solid content, in any case higher than 15%, and in particular ranging between 25% and 30%, is carried out in an installation comprising a vertical cylindrical fermentation tank 1 , without any partition, as well as all the internal mechanical equipment.
At the level of this tank 1 are provided for means for supplying 2 the material to be treated and means for discharging 3 the digested material, means 2 and 3 being formed of supply 2 and discharge openings 3 , respectively.
As shown in FIGS. 1 and 2 , the supply 2 and discharge openings 3 are arranged so as to maintain a unidirectional forced advancing of the material in a substantially horizontal plane, and over a major portion of the cross-section of the tank 2 . Indeed, opening or openings 2 for supplying the material to be treated are placed at the level of the wall of this tank 2 , having a circular form, substantially diametrically opposite to the opening or the openings for discharging 3 the fermented material. A unidirectional forced circulation is thus imposed on the material under fermentation in a horizontal direction thanks to a supply by thrust, preferably achieved by means of a pump, for example with a piston or screw.
FIG. 2 shows a preferred embodiment of such a tank 1 , where the supply openings 2 A, 2 B, 2 C as well as the exit openings 3 A, 3 B, 3 C are distributed over an arc of a circle the inscribed angle α of which, in any case smaller than 180°, is so determined that the material entering into the tank is distributed over a large surface of the cross-section of the tank. The direction of circulation of the material is shown by means of arrows.
Advantageously, the openings 2 A, 2 B, 2 C, on one side, and 3 A, 3 B, 3 C, on the other side, are connected by single conduits 4 and 5 , in order to ensure a uniform supply and/or exit flow rate of the material through these openings, and to achieve similar speeds of progression of the material over the full cross-section of the tank.
On the other hand, as shown in FIG. 1 , the supply 2 A, 2 B, 2 C and/or exit openings 3 A, 3 B, 3 C can advantageously be distributed at different heights on the wall of the tank.
The circulation is in addition favoured by homogenisation means 6 in the form of pipes 6 for injecting gaseous fluid under pressure at the level of the bottom 7 of the tank 1 .
One understands that the injection of gas under pressure induces a homogenisation by vertical sectors 8 in the tank, by imparting an ascending vertical movement to the material over the full height of the tank 1 . The vertical sectors 8 considered are defined by the location of the injecting pipes and advantageously adopt the shape of parallel sections.
The homogenisation means 6 are an essential element in the operation of the process and the installation according to the present invention. In FIG. 1 are shown the two components of the movement of the material under fermentation: horizontal progression H and the vertical movement V.
The horizontal progression H is achieved under the action of the thrust of the supply of the material to be treated.
The vertical movement V, favouring the fact that the material under treatment do not settle, is produced by the injection of fluid, in particular gas, under pressure G at the bottom of the tank.
Advantageously, the pressure of injection of the fluid at the bottom of the tank is higher than or equal to twice the static pressure in the tank. For example, for a material height of 20 meters inside the tank, the pressure of injection is higher than or equal to 4 bars.
As a matter of fact, by limiting the settling in a sector and in the tank in general, and by decreasing the risk for differential speeds of circulation to be created between the material, in particular inside one and the same sector 8 and in the tank in general, the means for vertical homogenisation contribute to the homogeneous advancing of the material injected into the tank, this advancing corresponding globally to that of the vertical sectors 8 .
The virtual division of the tank 1 into several sectors 8 occurs through the distribution of the injecting pipes 4 on the bottom of the fermentation tank 1 . Each sector 8 is individually supplied with gas under pressure. The gases are injected successively into each sector 8 and shifted in time.
FIG. 3 shows in particular the arrangement of these sectors 8 . The latter are arranged so that the bottom of the tank is virtually divided by ramps, numbered a to h, parallel to each other and perpendicular to the direction of progression of the material in the tank 1 , in short perpendicular to the plane D connecting the median supply 2 B and discharge openings 3 B. Thus, the injection into each sector 8 successively occurs from the ramp a on the side of the supply openings 2 A, 2 B, 2 C towards the ramp h on the opposite side corresponding to the discharge openings 3 A, 3 B, 3 C, favouring a movement in the direction of the forced unidirectional and horizontal circulation of the material.
Advantageously, ramps i and j perpendicular to the preceding ramps and located on the edges of the tank 1 complement these homogenisation means 6 . This can prove particularly favourable for the tanks having a very large volume, by limiting the idle volumes in the digestion tank 1 , which is essential for the proper operation of the process and the installation for the implementation of the process.
Generally speaking the absence of partitioning constitutes, in the invention, an advantage for the circulation of the material. From an economic point of view, this absence also results into a reduction of the manufacturing cost of the tank 1 .
According to a second variant of embodiment of a tank 1 shown in FIG. 4 , the bottom 7 of the tank 1 has a slope β, said slope β being so oriented that the material under fermentation, and in particular, if these are present, the heavy particles eventually settled on this bottom of the tank, move by gravity from the supply opening or openings 2 A, 2 B, 2 C to the discharge opening or openings 3 A, 3 B, 3 C. The angle of the slope β is adjusted with the nature and the grain-size distribution of the paste to be treated, so that the conveying is progressive and compatible with the transformation of the organic material under the action of fermentation.
Advantageously, at least one 3 D of the discharge openings is located in the lower portion of the wall of the tank 1 so that, if heavy particles are accumulated at the lower level of the bottom 7 of the tank 1 , they leave the enclosure by gravity.
According to this second variant of embodiment, the pipes 6 through which the fluid under pressure is injected extend horizontally on the inclined bottom 7 of this tank 1 and so that the fluid is directed in the same direction as the conveying of the material. The advantages of this arrangement are stated hereafter. Firstly, this arrangement permits to create in the perimeter close to the pipe a pneumatic thrust in the direction of the circulation of the material, which favours the transverse advance of said material and in particular of the heavy particles eventually settled on the bottom 7 of the tank 1 . Secondly, the penetration by gravity of these heavy particles into the opening of the pipes 6 is thus avoided.
Injecting pipes 6 for fluid under pressure will advantageously be arranged in front of the discharge opening or openings 3 D located at the lower level of the tank 1 , as shown in FIG. 5 . In this way, through these pipes 6 a mechanical or pneumatic action in order to free, should the case arrive, the whole or part of the opening or openings 3 D, within the framework of the maintenance of the installation, is allowed without any direct intervention on said openings likely to represent a major disturbance of the operation of the present device and process.
According to another feature, the present invention takes advantage of the geometry of the tank 1 to perform, on the one hand, an extraction and, on the other hand, a recycling by gravity of the fermented material.
Thus, the process according to the invention also allows a preferred extraction of the heavy inert materials eventually settled at the lower level of the fermentation tank.
It is recalled in this respect that the process and device according to the invention are intended at treating material formed of heterogeneous solid organic waste that may contain undesirable particles likely to settle in a fermentation tank, such as for example stones, glass or metal compounds.
As shown in FIG. 6 , at least one exit opening 3 D is connected through a valve 9 to a device 10 allowing the discharge of the digested material, advantageously designed in the form of a device 10 allowing their additional dehydration.
It is recalled in this respect that water proceeding from this dehydration can be used for the preparation of the solid organic waste the degradation of which is aimed by the present invention, for the preparation of the paste, which the installation is supplied with.
In the configuration according to the present invention, the heavy particles eventually settled at the lower level of the tank 1 are, upon opening the valve 9 , taken along by gravity in the flow of material, preferably in a first phase of extraction. The flow corresponding to this first phase is thus directed towards the device 10 allowing the discharge of the digested material.
On the other hand, in order to spawn the products before their entering into the tank 1 , a circuit for re-circulating 11 part of the digested material towards the supply openings 2 is provided for.
In this respect, it is recalled that according to the spirit of the invention, the latter seeks for a uniform circulation of the material in the tank. It is then possible to contemplate to control the speed of circulation of the material in the tank.
Since the process and device according to the invention refer to a continuous-digestion process and device, the result is that for a given quantity of material entering into the system is extracted an equivalent quantity of digested material.
Thus, another advantageous feature of this invention consist in conferring to said material, during the recycling of the fermented material at a high flow rate, a high circulation speed so as to take along the heavy particles eventually settled in the pipes.
The installation for implementing the process according to the invention comprises, for the recirculation circuit 11 , a connection external to the tank 1 , intervening between the discharge means 3 and the means 2 for supplying material to be treated.
According to a feature of the invention shown in FIG. 6 , at least one exit opening 3 D is connected to a storage device 12 , operating at atmospheric pressure, consisting of a feed hopper located on a supply pump 13 , via a pipe 14 equipped with at least one automatically controlled valve 15 . The opening of this valve 15 allows direct communication between the fermentation tank and the buffer storage formed by the device 12 .
Thus the static pressure generated by the height H of the material under fermentation in the tank 1 is transmitted directly to the material inside the pipe 14 .
By choosing the diameter of the pipes appropriately is achieved a very high material flow-rate during the period of opening of said valve 15 , much higher than the flow rate that could be ensured with only a pump of the same type as that being used for supplying the material. This high flow rate generates a high speed of circulation of the material, so that the heavy particles eventually settled are taken along in the flow of material. An obstruction of the pipes is thus avoided.
A suitable sequence of successive opening and closing of the valve permits to achieve high flow rates over short periods of time and, hence, punctually a high speed of circulation of the material in the pipes, while guaranteeing a selected resulting average flow rate.
To enhance the control of the flow rate, a pump can nevertheless advantageously complete this device.
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The invention relates to a process for anaerobic treatment of material having a solids concentration greater than 15% in a digester in the form of a sealed tank ( 1 ) equipped with means ( 2 ) for supplying material to be treated and means ( 3 ) for discharging digested material and also vertical homogenization means ( 6 ) in the form of injectors for injecting a gaseous fluid into the bottom ( 7 ) of the tank ( 1 ). Through distribution in the tank ( 1 ) of the material supply means ( 2 ) relative to the discharge means ( 3 ) and using vertical homogenization means ( 6 ) that guarantee the homogeneity of the material treated by vertical sectors ( 8 ) in the tank, conferred on the material in the tank ( 1 ) is a forced unidirectional circulation that is uniform throughout the entire cross section of this tank, and along one substantially horizontal component, between said supply means ( 2 ) and said discharge means ( 3 ). The invention also relates to an installation for implementing such a process.
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BACKGROUND OF THE INVENTION
This invention relates generally to gas turbine engines and, more particularly, to a fuel nozzle for a gas turbine engine.
Air pollution concerns worldwide have led to stricter emissions standards both domestically and internationally. Pollutant emissions from industrial gas turbines are subject to Environmental Protection Agency (EPA) standards that regulate the emission of oxides of nitrogen (NOx), unburned hydrocarbons (HC), and carbon monoxide (CO). In general, engine emissions fall into two classes: those formed because of high flame temperatures (NOx), and those formed because of low flame temperatures that do not allow the fuel-air reaction to proceed to completion (HC & CO).
Accordingly, at least one known industrial gas turbine application includes a steam injection system that is configured to inject steam into the combustor to facilitate reducing nitrous oxide emissions from the gas turbine engine. However, when the steam injection system is not in use, i.e. during dry operation, at least one known gas turbine engine utilizes at least one of an air or fuel purge to reduce the potential for cross-talk between adjacent fuel nozzles and/or to reduce backflow into the fuel nozzle caused by off-board steam system leakage. Cross-talk as used herein is defined as the inflow through a first fuel nozzle and outflow through a second fuel nozzle caused by a circumferential pressure distribution within the combustor. More specifically, at least one known gas turbine engine includes a relatively large steam circuit flow area, such that compressor discharge bleed air supply is insufficient to purge the fuel nozzles. Similarly, utilizing gas to purge the fuel nozzle results in a relatively small purge flow, which is insufficient to provide protection against the aforementioned situations.
BRIEF SUMMARY OF THE INVENTION
In one aspect, a method for delivering fuel in a gas turbine engine is provided. The method includes channeling fuel through the first passage such that fuel is discharged through the nozzle tip at least one primary discharge opening, channeling fuel through the second passage such that fuel is discharged through the nozzle tip at least one secondary discharge opening, and channeling steam through the third passage such that steam is discharged through the nozzle tip at least one tertiary discharge opening in a first operational mode.
In another aspect, a gas turbine engine fuel nozzle is provided. The gas turbine engine fuel nozzle includes an axis of symmetry extending therethrough, the nozzle body including a first passage extending coaxially therethrough, a second passage, and a third passage, the second passage circumscribing the first passage, the third passage formed radially outward of the second passage, and a nozzle tip coupled to the nozzle body, the nozzle tip including at least one primary discharge opening in flow communication with the first passage, at least one secondary discharge opening in flow communication with the second passage, and at least one tertiary discharge opening in flow communication with the third passage.
In a further aspect, a gas turbine engine assembly is provided. The gas turbine engine assembly includes a gas turbine engine, at least two manifolds coupled to the gas turbine engine, the at least two manifolds including a first manifold and a second manifold, the first manifold configured to deliver to the gas turbine engine a first gas, the second manifold configured to deliver to the gas turbine engine a first fuel; and at least one fuel nozzle. The fuel nozzle includes an axis of symmetry extending therethrough, the nozzle body including a first passage extending coaxially therethrough, a second passage, and a third passage, the second passage circumscribing the first passage, the third passage formed radially outward of the second passage, and a nozzle tip coupled to the nozzle body, the nozzle tip including at least one primary discharge opening in flow communication with the first passage, at least one secondary discharge opening in flow communication with the second passage, and at least one tertiary discharge opening in flow communication with the third passage.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of an exemplary gas turbine engine;
FIG. 2 is a cross-sectional view of an exemplary combustor used with the gas turbine engine shown in FIG. 1 ;
FIG. 3 is a schematic illustration of an exemplary fuel delivery system for the gas turbine engine shown in FIG. 1 ;
FIG. 4 is a cross-sectional view of an exemplary fuel nozzle that can be used with the gas turbine engine shown in FIG. 1 ;
FIG. 5 is an end view of a portion of the fuel nozzle shown in FIG. 4 ;
FIG. 6 is a cross-sectional view of the fuel nozzle shown in FIG. 4 during a first operational mode;
FIG. 7 is a cross-sectional view of the fuel nozzle shown in FIG. 4 during a second operational mode.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a schematic illustration of an exemplary gas turbine engine 10 including a low pressure compressor 12 , a high pressure compressor 14 , and a combustor 16 . Engine 10 also includes a high pressure turbine 18 , and a low pressure turbine 20 arranged in a serial, axial flow relationship. Compressor 12 and turbine 20 are coupled by a first shaft 24 , and compressor 14 and turbine 18 are coupled by a second shaft 26 . In one embodiment, gas turbine engine 10 is an LMS100 engine commercially available from General Electric Company, Cincinnati, Ohio.
In operation, air flows through low pressure compressor 12 from an upstream side 28 of engine 10 . Compressed air is supplied from low pressure compressor 12 to high pressure compressor 14 . Highly compressed air is then delivered to combustor assembly 16 where it is mixed with fuel and ignited. Combustion gases are channeled from combustor assembly 16 to drive turbines 18 and 20 .
FIG. 2 is a cross-sectional view of a combustor, such as combustor 16 , that may be used with gas turbine engine 10 . Combustor 16 includes an inner liner 30 and an outer liner 32 . Inner and outer liners 30 and 32 are joined at an upstream end 36 by a dome assembly 40 . The cross section shown in FIG. 2 is taken through one of a plurality of swirler assemblies 42 that are mounted on dome assembly 40 . A fuel line 44 delivers fuel to a fuel nozzle 46 that supplies fuel to an inlet 48 of swirler assembly 42 . Fuel is mixed with air in swirler assembly 42 and the fuel/air mixture is introduced into combustor 16 from an outlet 50 of swirler assembly 42 .
FIG. 3 is a schematic illustration of an exemplary fuel delivery system 60 that can be used with a gas turbine engine, such as gas turbine engine 10 (shown in FIG. 1 ). In the exemplary embodiment, fuel delivery system 60 includes a steam circuit 62 and a gas circuit 64 which respectively deliver a first gas, i.e. steam, and a first fuel, i.e. gas, to gas turbine engine 10 . Steam circuit 62 and gas circuit 64 are both metered and sized to achieve a pressure ratio within fuel delivery system 60 appropriate for the gas being delivered to gas turbine engine 10 . Steam circuit 62 delivers a metered steam flow to gas turbine engine 10 and gas circuit 64 delivers a metered first gas flow to gas turbine engine 10 .
Steam circuit 62 includes a connecting line 66 which extends from a metering valve (not shown) to a first manifold 70 . The metering valve is positioned between a steam supply source (not shown) and connecting line 66 . In one embodiment, the first gas supply source is a steam supply source. First manifold 70 is connected to a connecting line 72 which extends from manifold 70 to a plurality of fuel nozzles, such as fuel nozzle 46 , shown in FIG. 2 . Fuel nozzles 46 are coupled to gas turbine engine 10 and deliver the secondary steam and secondary gas flows to gas turbine engine 10 once gas turbine engine 10 has been operating for a predetermined length of time and is being accelerated from the initial idle speed.
Gas circuit 64 includes a connecting line 80 which extends from a metering valve (not shown) to a second manifold 82 . The metering valve is positioned between a gas supply source (not shown) and connecting line 80 . In one embodiment, the gas supply source is a natural gas supply source. In an alternative embodiment, gas supply source is a liquid fuel source. Second manifold 82 is coupled to fuel line 44 which extends from manifold 82 to fuel nozzle 46 . Fuel nozzles 46 are coupled to gas turbine engine 10 to deliver the first fuel to gas turbine engine 10 during initial operation of gas turbine engine 10 and while gas turbine engine 10 is operating during all operational conditions. In operation, fuel delivery system 60 is capable of delivering the steam and gas such that gas turbine engine 10 is capable of operating during all operational conditions.
FIG. 4 is a cross-sectional view of an exemplary fuel nozzle 100 that can be used with gas turbine engine 10 and system 60 (shown in FIG. 3 ). FIG. 5 is an end view of a portion of fuel nozzle 100 (shown in FIG. 4 ). Nozzle 100 includes a first fuel inlet 102 , a second fuel inlet 104 , and a steam inlet 106 . In the exemplary embodiment, first and second fuel inlets 102 and 104 are coupled to gas circuit 64 , and steam inlet 106 is coupled to steam circuit 62 . Fuel nozzle 100 also includes a nozzle body 110 , and a nozzle tip 112 . Nozzle body 110 has a first end 120 and a second end 122 . First fuel inlet 102 , second fuel inlet 104 , and steam inlet 106 are each positioned adjacent first end 120 and nozzle tip 112 is positioned adjacent second end 122 .
In the exemplary embodiment, first fuel inlet 102 extends from nozzle body 110 and includes a coupling 130 , and second fuel inlet 104 extends from nozzle body 110 and includes a coupling 132 which permits each of first and second fuel inlets 102 and 104 to be coupled to fuel line 44 (shown in FIGS. 2 and 3 ). Additionally, steam inlet 106 includes a coupling 134 which permits steam inlet 106 to be coupled to steam 72 (shown in FIG. 3 ).
More specifically, nozzle body 110 includes a first wall 140 that defines a first passage 142 that is positioned approximately along a centerline axis 143 of nozzle body 110 . In the exemplary embodiment, first passage 142 extends from coupling 130 to nozzle tip 112 and is configured to channel fuel from coupling 130 to nozzle tip 112 . Nozzle body 110 also includes a second wall 150 . In the exemplary embodiment, second wall 150 is coupled radially outwardly from first wall 140 , and substantially circumscribes first wall 140 such that a second passage 152 is defined between first wall 140 and second wall 150 . Accordingly, second passage 152 has a diameter 154 that is greater than a diameter 144 of first passage 142 . Nozzle body 110 also includes a third wall 160 . In the exemplary embodiment, third wall 160 is coupled radially outwardly from second wall 150 , and substantially circumscribes second wall 150 such that a third passage 162 is defined between second wall 150 and third wall 160 . Accordingly, third passage 162 has a diameter 164 that is greater than second passage diameter 154 . In the exemplary embodiment, third wall 160 forms an exterior surface 166 of nozzle body 110 .
In the exemplary embodiment, nozzle tip 112 , an end portion 167 and a body portion 168 that is coupled to and substantially circumscribes end portion 167 such that nozzle tip 112 has a substantially cylindrical cross-sectional profile. In the exemplary embodiment, nozzle tip 112 includes at least one first opening 170 that is formed through end portion 167 and is positioned along centerline axis 143 . More specifically, first opening 170 is configured to discharge fuel that is channeled through first passage 142 , through nozzle tip end portion 167 , and into combustor 16 . Nozzle tip 112 also includes a second plurality of openings 172 that are formed through nozzle tip end portion 167 , and are positioned radially outwardly from first opening 170 . In the exemplary embodiment, second plurality of openings 172 are configured to discharge fuel that is channeled through second passage 152 , through nozzle tip end portion 167 , and into combustor 16 . Nozzle tip 112 also includes a third plurality of openings 174 that are formed through nozzle tip end portion 167 , and are positioned radially outwardly from second plurality of openings 172 . In the exemplary embodiment, third plurality of openings 174 are configured to discharge steam that is channeled through third passage 162 , through nozzle tip end portion 167 , and into combustor 16 . In the exemplary embodiment, first, second, and third plurality of openings 170 , 172 , and 174 are each configured to discharge either fuel or steam, respectively, through nozzle tip 112 in a flow path that is substantially parallel with centerline axis 143 .
Nozzle tip 112 also includes a fourth plurality of openings 176 that are formed through nozzle tip body portion 168 , and are positioned upstream from third plurality of openings 174 . In the exemplary embodiment, fourth plurality of openings 176 are configured to discharge steam that is channeled through third passage 162 , through fourth plurality of openings 176 , and into combustor 16 . In the exemplary embodiment, fourth plurality of openings 176 are configured to discharge steam through nozzle tip body portion 168 in a flow path that is positioned at a predefined angle with respect to centerline axis 143 . Moreover, and in the exemplary embodiment, fourth plurality of openings 176 a diameter 180 that is less than a diameter 182 of third plurality of openings 174 that during operation a first quantity of steam is channeled through fourth plurality of openings 176 that is less than a second quantity of steam that is channeled through third plurality of openings 174 .
FIG. 6 is an enlarged cross-sectional view of fuel nozzle 100 (shown in FIG. 4 ) during a first operational mode. FIG. 7 is an enlarged cross-sectional view of fuel nozzle 100 (shown in FIG. 4 ) during a second operational mode. During operation, gas turbine 10 , and thus fuel nozzle 46 can be operated in either a first mode or a second mode. In the exemplary embodiment, the first mode is referred to herein as an active mode, i.e. steam is channeled through fuel nozzle 100 and into combustor 16 . Whereas, during the second mode, referred to herein as the inactive or dry mode, steam is not channeled through fuel nozzle 100 and into combustor 16 .
Accordingly, when nozzle 100 is operated in the active mode (shown in FIG. 6 ), steam is channeled from steam circuit 62 to nozzle 100 via coupling 134 . More specifically, steam is channeled from steam circuit 62 into third passage 162 . The steam is then channeled from nozzle body first end 120 to nozzle body second end 122 , and thus nozzle tip 112 . In the exemplary embodiment, during the active mode, steam is channeled through openings 174 and openings 176 in combustor 16 . More specifically, a first quantity of steam is channeled through openings 174 and a second quantity of steam, that is less than the first quantity of steam, is channeled through openings 176 . For example, since openings 174 have a larger diameter than openings 176 a majority of the steam is channeled through openings 174 in the active mode. Accordingly, channeling steam through openings 174 and 176 during the active mode facilitates increasing the fuel efficiency of gas turbine engine 10 .
Alternatively, when nozzle 100 is operated in the dry mode, steam is not channeled through nozzle 100 . More specifically, when nozzle 100 is operated in the dry mode, the air pressure drop across swirler 42 generates a pressure differential between openings 174 and openings 176 such that an airflow 190 is forced through openings 176 into third passage 162 and then through openings 174 . Thus, during the inactive mode, openings 176 facilitate purging fuel nozzle 100 . More specifically, during dry operation, the air pressure drop across swirler 42 facilitates providing the driving pressure for a purge flow across nozzle tip 112 . Moreover, through appropriate selection of the design variables, protection against circumferential pressure gradients and steam system leaks will be maintained without significantly impacting gas/steam emissions performance.
The above described fuel nozzle for a gas turbine engine is cost-effective and reliable. The fuel nozzle includes a separate steam injection circuit that is positioned on the outermost annulus of the fuel nozzle. Moreover, the nozzle stem forms the outer boundary of the steam circuit. Specifically, the above described fuel nozzle includes a series of orifices formed through the nozzle stem immediately upstream of the swirler/nozzle interface such that during active operation a fraction of the steam exits these “upstream holes,” while the remainder is injected at the tip. Whereas, during dry operation, the air pressure drop across the swirler provide the driving pressure for a purge flow across the nozzle tip. Through appropriate selection of the design variables, protection against circumferential pressure gradients and steam system leaks will be maintained without significantly impacting gas/steam emissions performance.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
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A gas turbine engine fuel nozzle includes an axis of symmetry extending therethrough, the nozzle body including a first passage extending coaxially therethrough, a second passage, and a third passage, the second passage circumscribing the first passage, the third passage formed radially outward of the second passage, and a nozzle tip coupled to the nozzle body, the nozzle tip including at least one primary discharge opening in flow communication with the first passage, at least one secondary discharge opening in flow communication with the second passage, and at least one tertiary discharge opening in flow communication with the third passage.
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BACKGROUND OF THE INVENTION
Dual concentric drill pipe systems are particularly useful for air lift drill techniques, especially air lift reverse circulation drilling. A system for reverse circulation dual tube drilling is disclosed in Henderson U.S. Pat. No. 3,208.539.
In conventional circulation, single tube drilling systems, drilling fluid (e.g., mud or water) is pumped down the drill pipe to the bit, and returns to the surface in the annular space between the drill pipe and the hole wall (the hole annulus). An accepted technique involves the injection of compressed air into the drilling fluid, usually by means of an auxiliary air line, to assist in lifting the cuttings from the bottom of the hole to the surface.
The use of dual concentric drill pipe can greatly expand the possible applications of the air lift technique. In a dual tube system, such as shown in the above mentioned Henderson patent, an inner tube is disposed concentrically within an outer tube, thus defining a continuous annular flow passage between the two tubes (the pipe annulus or annular passageway) and a continuous flow passage through the inner tube (the central passageway). Air lift techniques can be used in such systems in a variety of ways. For example, a heavy drilling fluid such as mud or water can be pumped or allowed to pass down the hole through the hole annulus to the bit. At the same time, compressed air is pumped down the pipe annulus. The cuttings and drilling fluid then pass upward to the surface through the central passageway inside the inner tube. The compressed air in the pipe annulus is either injected into the inner tube at a location above the bit or passes around the bit and into the inner tube, and assists in lifting the cuttings upward. As another example, it might be desired to drill using only air, with no circulation in the hole annulus, such as in water bearing formations. In such an application, air would again be pumped down the pipe annulus, around the bit and into the inner tube. This air assists in the cutting process and would also serve to lift the cuttings and formation water out of the hole into the inner tube.
In such applications, it has been found that pump efficiency and lifting capacity may be greatly enhanced by introducing compressed air in one or more stages along the length of the drill string. It has also been found that the most efficient and desirable method for injection of air requires a system which minimizes turbulence and which causes the air to enter the water or mud stream in the inner pipe in extremely small bubles.
SUMMARY OF THE INVENTION
The present invention provides an air lift diffuser staging sub capable of injecting air into the inner tube of a dual tube drilling system in a very efficient manner at any desired point along the drill string. This is achieved by providing a sub which includes inner and outer tubular members concentrically disposed and adapted to be joined with corresponding inner and outer pipes of a dual tube string. An annular chamber is provided in the inner tubular member, with ports providing fluid communication between the pipe annulus and the chamber. A check valve in the chamber prevents the flow of fluid back from the chamber into the pipe annulus. A series of small, regularly spaced apertures provides fluid communication between the chamber and the central passageway within the inner tube. Thus air from the annulus is allowed to enter the chamber and is diffused smoothly into the central passageway.
The general object of the present invention is to provide an air lift diffuser staging sub for use in air lift reverse circulation techniques, which greatly increases air pump efficiency and the lifting capacity of the system. Other objects of the invention will become apparent upon consideration of the following description, with reference to the appended drawings, in which:
FIG. 1 is a transverse sectional view of an injection sub embodying the present invention;
FIG. 2 is a fragmentary cross sectional view taken on the line 2--2 of FIG. 1; and
FIG. 3 is a view similar to that of FIG. 2, taken on the line 3--3 of FIG. 1.
DESCRIPTION
With reference to the drawings, there is shown in FIG. 1, as an example of one form in which the present invention may be embodied, an injection sub generally designated by the numeral 10. The injection sub 10 includes an outer tubular member 12, and an inner tubular member generally designated by the numeral 14 disposed concentrically therein. In the embodiment shown in FIG. 1, the inner tubular member 14 actually comprises a first inner tubular member 16 and a second inner tubular member 18, although it is possible to construct the inner member 14 as a single unit.
At the upper end of the injection sub 10 is shown a portion of an element of a dual concentric drilling system, generally designated by the numeral 20. The element 20 may be, for example, a segment of dual tube pipe having concentric outer and inner pipes 22 and 24, respectively. Similarly, at the lower end of the sub 10 there is shown a portion of a dual tube drilling element having respective outer and inner pipes or tubes 26 and 28. The inner tubes 24 and 28 are concentrically disposed within the outer tubes 22 and 26, respectively, and together these tubular members define an annular passageway or pipe annulus 30 and a central passageway 32.
The outer tube 12 of the injection sub 10 is connected at each end to the outer tubes 22 and 26 of the dual tube elements in familiar fashion, as by a threaded pipe joint 34. The inner tubular member 14 of the injection sub 10 communicates at each end with the inner tubes 24 and 28 of the dual tube elements. In this manner, the annular passageway 30 and the central passageway 32 are maintained without interruption through the length of the injection sub 10.
In the embodiment shown in FIG. 1, the upper end 36 of the first inner tubular member 16 is adapted for telescopic interconnection with the inner pipe 24. A seal box 38, containing O-rings 40 is affixed to the lower end of the inner pipe 24, and the upper end 36 of the inner tube 16 is inserted therein. The O-rings 40 provide a slidable fluid tight seal, thus isolating the central passageway 32 from the annular passageway 30. In like manner, the lower end 42 of the second inner tubular member 18 is provided with a seal box 44 containing O-rings 46. The upper end of the inner pipe 28 is telescopically disposed within the seal box 44, again providing a fluid tight seal. The seal box 44 is preferably removably attached to the lower end 42 of the second inner tubular member 18, as by threads 48, to permit access to the interior of the sub 10. The seal box 44 may also include a radial spider or centralizing lugs 50. Gaps 52 are preferably provided between the inner member ends 36 and 42 and the ends of the inner pipes 24 and 28, respectively, to accommodate a limited degree of axial movement as disclosed in Henderson U.S. Pat. No. 3,208,539.
The inner tubular member 14 of the sub 10 is preferably attached to the outer member 12 at one point only, or along only a limited portion of their lengths, or the members 12 and 14 otherwise include means to accommodate relative expansion or contraction of the two members, also as disclosed in Henderson U.S. Pat. No. 3,208,539. As shown in FIG. 1 first inner tubular member 16 is suspended within the outer member 12 by means of a spider or lugs 54 which rest on a corresponding shoulder 56 formed in the outer member 12. A snap ring 58 serves to maintain the spider 54 against the shoulder 56. Flow passages 60 in the spider 54 are provided to preserve the flow path in the annular passageway 30.
The upper end 62 of the second inner tubular member 18 fits snugly, in concentric or coaxial fashion, within the lower end 64 of the first inner tubular member 16. The members 16 and 18 define therebetween an annular chamber 66. A generally annular valve seat 68 is provided at the lower end 64 of the first inner member 16, to isolate the chamber 66 from the annular passageway 30. The valve seat 68 is preferably removably attached to the lower end 64 of the tubular member 16, as by threads 70, to permit access to the interior of the chamber 66. The valve seat 68 is provided with a series of ports 72 which permit fluid communication between the annular passageway 30 and the chamber 66.
Disposed within the chamber 66 is a generally annular check valve 74 which is positioned concentrically about the outer surface of the second inner member 18 so that it may slide axially with respect thereto. The valve 74 responds to a pressure differential between the annular passageway 30 and the chamber 66 to open the ports 72 and permit fluid to pass there through; conversely, when the pressure differential is reduced, gravity causes the check valve 74 to close the ports 72.
The upper end 62 of the second inner tubular member 18 includes a series of circumferentially spaced grooves or apertures 76 which permit fluid communication between the chamber 66 and the central passageway 32. Thus, a fluid, such as compressed air, is pumped down the pipe annulus 30, and by operation of the check valve 74 a portion of it is permitted to pass into the chamber 66 through the ports 72. From the chamber 66 the air passes through the grooves or apertures 76 into the central passageway 32.
The ports 72 are preferably small round holes, regularly spaced circumferentially around the valve seat 68. The apertures 76 are also regularly spaced about the upper end 62 of the second inner member 18, and are preferably substantially smaller than the ports 72. The aperture 76 should be made as small as possible without sacrificing the air lift capability of the system. It is preferable to make the apertures 76 small enough to achieve virtual diffusion of the air into the central passageway 32. It is also preferably to position the aperture 76 so that the air exits therefrom along the inner surface of the inner tube 16, creating a minimum of turbulence. Although various sizes and spacings of the ports 72 and apertures 76 are permissible, it has been found that excellent results may be achieved by making the ports 72 one-sixteenth inch in diameter with a center to center spacing between ports of one-quarter to three-eighths inch, and by reducing those corresponding dimensions by more than one-half in the case of the size and spacing of the aperture 76.
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An injection sub for use with a string of dual concentric drill pipe, having inner and outer tubular members concentrically arranged to mate with the inner and outer pipes of the drill string to provide continuous isolated annular and central passageways, is particularly characterized by an annular chamber in the inner member. Ports permit the flow of fluid from the annular passageway to the chamber, and apertures permit fluid flow from the chamber to the central passageway. An annular check valve in the chamber cooperates with the ports to prevent flow from the chamber to the annular passageway.
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RELATED APPLICATIONS
[0001] This application: is a continuation (divisional) of U.S. patent application Ser. No. 14/607,680, filed Jan. 28, 2015; which claims the benefit of U.S. Provisional Patent Application Ser. No. 61/965,339, filed Jan. 28, 2014, both of which are hereby incorporated by reference in their entirety.
FIELD OF INVENTION
[0002] This application relates to structural engineering, particularly lateral bracing systems to resist earthquakes or similar episodic forces.
BACKGROUND ART
[0003] Structural engineers must often design structural members to resist large forces that may occur infrequently (such as earthquake forces) but whose failure would be catastrophic. Economy and reliability are both important considerations. Many existing buildings throughout the world were constructed before the actions of earthquakes were understood and such understanding was applied to construction methods. The replacement value of existing buildings that are exposed to earthquakes in the city of San Francisco alone is 190 billion dollars. This includes over $100 billion in replacement value for wood-frame residential buildings that were built before construction methods provided adequate protection from earthquakes. Worldwide, the replacement value of buildings vulnerable to earthquakes is likely in the trillions of dollars.
[0004] One prominent vulnerability in existing buildings is the “soft, weak, or open-front” (hereinafter referred to as “SWOF”) condition. A common cause of SWOF condition is a large storefront window or garage door opening that substantially reduces the availability of bracing elements in a building to resist horizontal earthquake forces. Maintaining the door opening or display space precludes certain types of strengthening measures such as diagonal braces or shear walls, which account for significant prior art in the general category of lateral force resisting systems.
BRIEF SUMMARY OF THE INVENTION
[0005] A yield link connection for use in bracing structures against lateral loads, the connection comprising a first structural member fixed to a base or foundation, and to which a yield link is connected. The yield link connects the first structural member to the structure in need of bracing. The yield link is created by cutting out a portion of material from a standard rolled steel structural section. The shape and dimensions of the cutout are designed so that the remaining elements of the yield link become separate bending elements. These separate elements behave as fixed-fixed members with predictable yielding, creating four plastic hinge zones around the cutout. High hysteretic damping is achieved through designing the cutout so yielding occurs in a large amount of the steel volume remaining adjacent to the cutout. The cutout is further designed so that yielding occurs in the yield link before it occurs in the first structural member. Clearance is provided between the first structural member and the yield link to limit relative movement between the members to a predetermined amount. Should the yield link need to be replaced after an episodic event, removal of the damaged yield link is easy compared to prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 View showing yield link assembled with cantilevered structural member
[0007] FIG. 2 a Yield link—one embodiment
[0008] FIG. 2 b Yield link—alternative embodiment
[0009] FIG. 3 Section view of assembled yield links and structural member
[0010] FIG. 4 Detail of cutout in yield link
[0011] FIG. 5 Schematic diagram of “Fixed-fixed” bending member, with associated shear force and bending moment diagrams
[0012] FIG. 6 Schematic diagram of “Fixed-pinned” bending member, with associated shear force and bending moment diagrams
[0013] FIG. 7 a Schematic diagram showing solid bending member with cutout in web
[0014] FIG. 7 b Schematic diagram showing solid bending member with cutout in web, deforming under lateral load
[0015] FIG. 8 a Schematic diagram showing a conventional moment-column subjected to lateral load
[0016] FIG. 8 b Schematic diagram showing deformation of moment-column subjected to lateral load
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The two most common methods used to brace existing buildings with SWOF conditions are “moment-frames” and “moment-columns” (also called “cantilevered columns”). A moment-frame comprises two vertical members (usually one on each side of the large door or window opening) with a horizontal member rigidly connected to the tops of the vertical members. Moment-frames are almost always made of commonly available structural steel components. The members may be welded together in place—which presents the risk of fire—or bolted together. In almost all cases welding is required—which even if it is done in a fabrication shop adds substantial expense to the process.
[0018] Moment-frames are very difficult to fit into an existing building without first removing or relocating existing utilities such as water and gas piping, electrical wiring or conduits, sewer lines, ventilating ducts, etc. Sometimes the configuration of the building makes installation of a moment-frame impossible without making the garage door opening narrower or lower, or both.
[0019] Modern moment-frames have been tested fairly extensively and their performance in earthquakes is expected to be fairly predictable.
[0020] Moment-columns essentially act as very stiff flag-pole-like elements: the base of the moment-column is attached to, or embedded in, a solid foundation. The top of the column attaches to the structural framing above the SWOF condition to provide stability for the structure above. Like moment-frames, moment-columns are usually constructed using standard steel members. A moment-column generally consists of a single length of steel wide-flange or a hollow structural steel tube. One advantage that moment-columns have over moment-frames for strengthening existing residential constructions is that a single column location is often all that is needed to sufficiently strengthen the construction.
[0021] Moment-columns are not considered to perform as reliably in earthquakes as moment frames, especially when the structural system relies on only a single moment-column. Moment-frames also provide more structural redundancy; at least two regions of the moment-frame must yield before it fails catastrophically, versus a moment-column that would fail when the base of the column yields. Therefore the building codes in the US require that a moment-column system be designed for much greater earthquake forces than a moment-frame system, all other things being equal. This requirement is intended to create a safety factor which will assure that moment-columns will be no more prone to failure than moment-frames.
[0022] Moment-columns have two major drawbacks. First, they require large safety factors under the current building codes. Second, they are very difficult to replace once they have deformed during an earthquake—especially if they are embedded into a concrete foundation, which is the easiest way to install them.
[0023] Model building codes determine required safety factors based in part on the redundancy of a structural system. One such “safety factor” is known as the response modification factor, symbolized as R. The model building code used in the US tabulates values of R for various building systems: Moment-frames, cantilevered (moment) columns, light-frame construction with wood-panel shear walls, etc. Depending on the value of R assigned to a particular structural system, structural engineers must design for much greater forces for some systems.
[0024] Consider two buildings that are identical except for the bracing systems; one building is braced with wood-panel shear walls and the other is braced with moment-columns. The seismic force that must be considered when designing the building braced with moment-columns will be from 2.6 to 5.2 times greater than the force for the shear-wall-braced structure. Compared to a structure braced with moment-frames, the design force for moment-column bracing may be as much as 6.2 times greater.
[0025] The weight required for a moment-column member is very closely related to the force it must resist. When a moment-column is being installed in an existing building it is generally impossible to lift members into place with an overhead crane. Reducing the weight of members to the point that workers can install them without using hoists would result in substantial reduction of construction costs.
[0026] Using a smaller safety factor would result in construction cost savings throughout the structural system, not just in the moment-column itself. The current model building code requires applying the safety factor for a moment column not just to the column itself, but also to all structural elements throughout the building that resist forces in the same direction as those resisted by the moment-column. This requirement implies at the very least doubling the strength of all components of the earthquake-force-resisting-system over what would be required for other systems.
[0027] Bracing methods for buildings must be strong enough to resist the imposed loads. They must also provide sufficient stiffness to keep the structure from deforming under the imposed loads, otherwise excessive damage results. In some cases structural elements that are not part of the bracing system can fail if too much movement is allowed.
[0028] A moment-column fixed at its base will deflect laterally when a lateral load is imposed at the top. The amount of deflection depends largely on the height of the column, magnitude of the imposed load, column material, structural properties of the column, and the rigidity of the base connection and foundation. Structural connections that allow the column to lean, even slightly, before developing full resistance to the imposed load are not desirable. Base connections that allow any slip or yielding lead to the deflection being magnified by the height of the column. For example, consider a column of completely rigid material in the shape of a rectangular prism with sides one foot wide, and a height of eight feet. If the column is allowed to rock slightly before its base connection fully engages, the slight rocking is magnified by the ratio of the column's height to its width. In this case a yield link at the base of the column that elongates by ⅛ inch would result in the top of the column deflecting 1 inch. Placing a yield link as close to the top of the column as possible will reduce movement of the braced structure, thus reducing damage.
[0029] Back-up elements in a structural system that provide secondary load resistance increase the reliability of the system. Such elements are sometimes called “fail safe” mechanisms. In many existing buildings, back-up elements are provided by ignoring the strength of “non-structural” materials such as plaster and wall-board. Providing more reliable and purposefully designed elements would be beneficial.
[0030] Many existing constructions are built of “light-frame” materials, typically lumber framing members. These materials can provide adequate bracing when lateral loads are distributed over a sufficient number of members. Building materials used in most light-frame constructions do not lend themselves to bracing against highly concentrated lateral forces.
[0031] Structural steel members are well-suited to resisting concentrated forces that may be presented during earthquakes. Structural steel members and connections are common-place in larger constructions such as high-rise buildings. Connections and members that resist hundreds of thousands of pounds or more are commonly made using various fabrication methods including bolting and welding. The great expense of such connections is justified in large buildings because relatively few of them are needed on a per-square-foot basis of building size. U.S. Pat. No. 7,874,120 B2 to Ohata et al (2011) and U.S. Pat. No. 6,681,538 B1 to Sarkisian (2004) claim connections that provide controlled yielding properties, but are prohibitively expensive for light-frame structures.
[0032] Light framed constructions such as dwellings have included a number of bracing systems in the past. The method most frequently used in current light-framed construction is use of structural elements known as “shear walls.” Shear walls are generally built on site using ordinary construction materials such as lumber, plywood, and nails. Shear walls require significant length along the sides of a construction to provide adequate lateral bracing. Large window or door openings are the very reason a SWOF condition exists in the first place; encroaching into the width of existing windows or doors to install shear walls changes the functionality of a building and is not an acceptable solution. Prior art has attempted to reduce the required bracing length of shear walls by introducing inventions of greater strength than could be achieved using ordinary construction materials. Even these improved systems do not have the strength required to resist high loads within the narrow confines of SWOF buildings. For example, commercially available products are manufactured under patent US20050126105 A1 to Leek, Perez, and Gridley (2005). The narrowest dimension manufactured is 12 inches. This product is rated to resist a lateral load of less than 1,000 pounds; demand can easily be 10 times this amount, making this product inadequate for bracing many existing constructions.
[0033] Besides relatively low strength, the products currently in production are generally available only in incremental sizes intended for new constructions. Existing buildings often require sizes that must be specially manufactured at greater expense, often resulting in construction scheduling delays.
[0034] As discussed earlier, moment-frames have features that make them completely unacceptable for use in many existing constructions and therefore are not considered as applicable prior art. One exception is the patent to Pryor and Hiriyur (2011) described in the following section.
[0035] Yield links are purposely designed to focus earthquake or other environmental forces into structural components specifically intended to absorb energy through the yielding of a ductile material such a steel. Ideally the yield links would be easily-replaceable structural components.
[0036] Ductile materials will yield in three ways: in shear, bending, or axially (due to tensile or compressive forces). Yield links using each of these principles exist. U.S. Pat. No. 5,533,307 A to Tsai and Li (1996) uses triangular plates rigidly fixed along one edge and loaded at the opposite apex, orthogonally to the plane of the plate. This causes the plate to yield under bending stresses generally uniformly over the entire area of plate; bending stresses in the steel increase uniformly as distance increases from the point of applied load, as does the strength of the ever-widening plate section. This is known as the “Triangular-plate Added Damping and Stiffness” (TADAS) concept. Background for U.S. Pat. No. 5,533,307 A describes the original concept as “having significant drawbacks” in that it is difficult to fabricate and assemble; however, the system illustrated under that patent still requires expensive fabrication and welding, and would only be suited to bracing very large constructions.
[0037] A lateral bracing system under patent U.S. Pat. No. 3,963,099 A to Skinner and Heine (1976) uses a ductile member rigidly attached to a building foundation. The member extends vertically from a fixed base (foundation) to the underside of the superstructure of the building. The top of the member engages a bracket attached to the superstructure to transmit lateral forces to the foundation. This system is meant for situations where the superstructure and foundation are separated by only inches, and is thus not suitable where the superstructure that needs bracing is several feet above the foundation.
[0038] U.S. Pat. No. 5,630,298 A to Tsai and Wang (1997) uses plates configured to yield in shear, with various welded stiffeners and end plates. This system is also exceedingly complex for economical use in all but very large constructions.
[0039] Patent US20110308190 A1 to Pryor and Hiriyur (2011) shows a moment-frame connection that includes a yield link described as yielding in tension or compression. This link is used to connect a beam to a column in a moment-frame, and requires the use of a restraining member to prevent the link from buckling during compression loading. The buckling restraint and yield link configuration would be difficult to access if the yield link needed to be replaced.
[0040] Engineers have learned the importance of inducing yielding of structural members at specific locations as a way to keep maximum bending stresses from occurring at vulnerable connections. One method of inducing yielding is the “reduced beam section” (RBS) method. In the RBS method, sections of flanges are cut away from a beam to reduce its strength by a predetermined amount. This method is described in U.S. Pat. No. 6,412,237 B1 to Sahai (2002) and U.S. Pat. No. 5,595,040 A to Chen (1997). A similar method is used in the patent to Pryor and Hiriyur (2011) cited above, wherein their yield link is created in the commercially available embodiment of their invention by reducing the stem in section of a “wide tee” shaped steel structural member or similar.
[0041] U.S. Pat. No. 6,012,256 A to Aschheim (2000) describes a method to reduce structural sections of members such that their webs will yield in shear at a predetermined loading level to protect more vulnerable structural components. This method does not expressly consider local buckling effects of the thin web elements that would remain adjacent to the voids in the modified member. Such buckling, if it occurred, could lead to sudden and possibly catastrophic failure of the member. Bracing the web elements would typically be done with welded stiffeners, which increases cost of fabrication.
[0042] In accordance with one embodiment, a cantilevered connection method that includes a structural member modified by removal of portions of the member in such a manner as to induce yielding under predetermined loads, said structural member(s) being mounted to a second structural member and the superstructure of a building in a manner that provides bracing during an earthquake.
[0043] Accordingly several advantages of one or more aspects result. For example, an economical and easy-to-fabricate connection, requires no welding. It provides an easily-replaceable yield link, improving the ductility and redundancy of the bracing system. It provides hysteretic damping, allowing bracing of structures with minimal disturbance to existing utilities or encroachment into wall openings. It includes a method to retrofit previously-strengthened buildings to provide some or all of the preceding advantages. Other advantages of one or more aspects will be apparent upon considering the drawings and description.
[0044] FIG. 1 shows one embodiment consisting of yield link 11 with web cutout 12 assembled to column 10 using connectors 15 through matching holes in yield link 11 and column 10 (the exact number and location of connectors 15 is not important to the invention). Framing connection hole 14 allows yield link 11 to be connected to the construction in need of bracing. Clearance 19 between link 11 and column 10 limits movement of link 11 with respect to column 10 . Column 10 is attached at its base (not shown) by suitable means to provide relative fixity. The specific method of base attachment is not important to the present invention, and will be familiar to those possessing ordinary skill in the arts.
[0045] FIG. 2 a and FIG. 2 b show two embodiments of the yield link 11 . Location of web cutout 12 is symmetric about the longitudinal axis of yield link 11 . The shape of web cutout 12 shown is not intended to limit the shape of web cutout 12 in other embodiments.
[0046] Placement of column connection holes 13 and framing connection hole 14 are not important to the present invention, and their location and number will vary. Connection requirements can be determined by those possessing ordinary skill in the arts.
[0047] Length of yield link 11 , along with the shape and location of web cutout 12 are very important to proper performance. These properties are subject to the brace loading, geometry and dimensions of the particular construction in which the present invention is installed, based on further explanation that follows.
[0048] The shape and dimensions of web cutout 12 depend on the material of which yield link 11 is made, allowable lateral displacement, and other factors. These determinations can be made by those possessing ordinary skill in the arts, considering at least the following:
[0049] Yield link 11 and web cutout 12 must be designed such that yield link 11 will yield prior to yielding occurring in column 10 . A conventional cantilevered column would yield at the point of maximum moment as indicated in FIG. 6 . A suitable safety factor must be applied as prudent or required by applicable codes (see also FIG. 3 ) The widest remaining portion at cutout 17 must be restricted such that local buckling of yield link web 11 a does not occur (or a standard steel member for yield link 11 is selected with a thicker web 11 a ). As an alternative (not shown) an element or system could be provided that would restrain web 11 a from buckling. Narrowest remaining portion at cutout 16 would need to be minimized to the thickness of yield link flange 11 b to maximize yielding of the material remaining on either side of web cutout 12 . Dimension of web cutout 12 along the longitudinal axis of yield link 11 will depend on the allowable lateral movement of the structure to be braced in accordance with relevant building codes. Lateral movement must also be limited so that bending strain in the material remaining on either side of web cutout 12 does not lead to low-cycle fatigue failure of the material used for yield link 11 . Strains will be reduced if the dimension of web cutout 12 is increased along the longitudinal axis of yield link 11 . The moment in the overall section increases closer to the fixed attachment point (see FIG. 6 ). Greater moment induces greater local compressive or tensile bending stress in flanges 11 b due to overall bending moment acting on the gross section of yield link 11 . Location and length of web cutout 12 must consider buckling of the pseudo-columns 30 a as shown in FIG. 7 a.
[0050] The preceding determinations are more fully described in “Soft Story Retrofits for the Real World: Cantilevered Column Modifications for Increased Ductility and Redundancy” by Thor Matteson, S E and Justin R. Brodowski, M S, EIT, Structural Engineers Association of California, 2014 Convention Proceedings.
[0051] FIG. 2 b shows an embodiment where web cutout 12 extends beyond the “effective” widest remaining web portion intended to yield 17 a. This configuration may be effective in further reducing stress concentrations around web cutout 12 .
[0052] FIG. 3 shows a section view of two yield links 11 sandwiching a column 10 . One yield link 11 is secured on each side of column 10 (represented here as a wide-flange member). This figure illustrates yield link web 11 a and yield link flange 11 b, as well as clearance 19 . Clearance 19 may be provided so a pre-determined lateral movement of the upper portion (as shown in figures) of yield link 11 will cause flange 11 b to contact the inside face of flange of column 10 . This would provide further structural redundancy in the case that the yield link 11 failed.
[0053] FIG. 4 shows a detail area of the web cutout 12 following the general shape of the embodiment illustrated in FIG. 2 a . Inside radius 18 is intended to reduce stress concentration at the transition from web cutout 12 to intact section of yield link 11 .
[0054] FIG. 5 shows a representative fixed-fixed member 30 with fixed end conditions 31 at both ends, with a lateral load “V” applied at the connected ends. The associated shear force and bending moment diagrams are given for the member under the loading shown.
[0055] FIG. 6 shows a representative fixed-pinned member 32 with fixed end condition 31 at the bottom of the figure and pinned end condition 33 at the top of the figure. A lateral load “V” is applied at the connected ends and the associated shear force and bending moment diagrams are shown for the given loading.
[0056] FIG. 7 a shows a schematic member as used for the yield link. This would be an ordinary bending member except for the web cutout 12 , which creates two pseudo-columns 30 a on either side of web cutout 12 . The pseudo-columns 30 a both take on the behavior of fixed-fixed member 30 as shown in FIG. 5 . Adjusting the dimensions of web cutout 12 allows great control over determining the lateral load that induces yielding, and where the yielding occurs. Yield link 11 has four regions that will undergo yielding because of web cutout 12 , namely above and below the midpoint of pseudo-columns 30 a shown in FIG. 7 a . If an unmodified section (from which web cutout 12 was removed) deformed due to bending stresses, it would result in the yield link flanges 11 b yielding only in tension or compression. Providing yield links 11 on both sides of column 10 (as shown in FIG. 3 ) gives eight distinct regions that will undergo yielding, compared to two regions in a conventional moment column. This is a significant increase in system redundancy.
[0057] FIG. 7 b illustrates how the member in FIG. 7 a would deform under load.
[0058] FIG. 8 a shows a conventional moment-column under load; FIG. 8 b shows how the same column would deform. Such deformation would lead to the left side of the column yielding in compression and the right side yielding in tension (typical behavior for a bending member). Comparing FIGS. 8 a & 8 b and FIGS. 7 a & 7 b , we see that the configuration of the present invention leads to reverse-curvature bending in the elements adjacent to the web cutout. Since yielding takes place in four discreet regions instead of two, the present invention has much greater structural redundancy than a conventional bending member.
[0059] The operation of the present invention is essentially the same as a conventional moment-column, save for replacement of yield link(s) 11 . Referring to FIG. 1 , a structural member is provided with a rigid connection at its base (represented as column 10 ). Identical yield link(s) 11 are attached to both sides of the web of column 10 using appropriate connectors 15 . The structure to be braced is connected to yield link(s) 11 through framing connection hole 14 . If an earthquake or other episodic event creates sufficient force in the yield link(s) 11 to cause them to deform, connectors 15 may be removed to allow replacement of link(s) 11 .
[0060] The present invention may be used to strengthen buildings or other structures against forces induced by other than earthquakes, and it may be used in new construction, and/or may include materials other than steel, in alternative embodiments of the invention.
[0061] The yield link connection presented allows a versatile method to induce controlled yielding at predetermined loads. Such yielding can absorb large amounts of energy through hysteretic damping, offering protection to the braced structure above.
[0062] Additional advantages to the present invention include several structural results. For example, the yield link(s) can be formed from rolled steel sections that are available worldwide in a large variety of sizes and thicknesses. Hysteretic damping can be achieved efficiently by designing the yield link to simultaneously yield along the height of web cutout. This system provides up to four times as many discrete yield zones as compared to a conventional moment-column.
[0063] Further testing may result in significant reductions in design forces required by model building codes for this system, based on increased ductility and redundancy. Such reduction would make this system much more economical to install than current moment-columns. Using a moment column allows greater flexibility in locating the bracing system than does a moment-frame.
[0064] Selecting appropriately matched column and yield link to give a desired clearance between their flanges allows for a maximum deflection at which point a “fail-safe” limit in yielding of yield link occurs. The yield link can be easily replaced if damaged during episodic loading. It requires no welding, resulting in reduced costs and elimination of related fire hazards in cases where field welding would otherwise be needed. Also it is relatively light-weight and easily handled in a fabricator's shop, facilitating economical fabrication.
[0065] Yield links can be paired with supporting columns to provide a wide variety of clearance between link and column. This allows for designing a variety of strengths and deflections that the system permits. Under current building code requirements, conventional moment columns are severely restricted in practical use. The present invention is expected to provide ductility and redundancy that would allow using column systems to brace a much wider range buildings. Using this method could save substantial construction costs in millions of buildings currently vulnerable to earthquakes.
[0066] The present invention may be embodied in other specific forms without departing from its purposes, functions, structures, or operational characteristics. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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A yield link connection for use in bracing structures against lateral loads connects a first structural member, fixed to a foundation to the structure in need of bracing. The yield link is created by cutting out a portion of material from a standard rolled steel structural section, so the remaining elements of the yield link become separate bending elements with predictable yielding, creating plastic hinge zones around the cutout. Should the yield link need to be replaced after an episodic event, removal of the damaged yield link is easy compared to prior art.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to electronic parts mounted on printed circuit boards, and specifically to the technology of mounting electronic parts on printed circuit boards.
2. Description of Related Art
Conventional soldering apparatuses solder electronic parts on printed circuit boards all at once, as is the case with mass production. However, soldering is performed differently in the case of soldering pins which are adjacent to each other and separated by an extremely small space. The soldering pins are provided on adjacent electrode units which are likewise separated by an extremely small space corresponding to the separation of the pins on the printed circuit board. Machines which use this setup include a thermal head of a facsimile machine and a printer. In such a case, soldering is performed manually for each pin in order to prevent the formation of a soldering bridge.
For example, FIG. 1 shows a conventional manufacturing process for a printed circuit board. First, copper 2 is provided (step 1) on the board 1 as a conductive member. The board 1 is formed of phenol resin or a similar material.
Ink 3 is then coated (step 2) by printing on a section of the copper 2 on which a pattern is formed. The pattern is formed according to a pre-designed pattern arrangement. A portion of the copper 2 outside of the section on which the ink 3 is printed is removed by etching (step 3). Then, the pattern 4 is formed on the board 1 by removing the ink 3 which remained defining the pattern (step 4).
Next, in order to prevent short circuits between patterns 4 during soldering, a covering member 6 is provided on the pattern 4 and the board 1 by printing using a printing sheet having a printing pattern. The printing sheet has a transferring pattern except for the positions corresponding to the electrode units 5 in the patterns 4 and the covering member 6 is coated by insulated material through the transferring pattern (step 5). As a result, the board 1 and the patterns 4 are insulated except for the electrode units 5, and short circuits between the patterns 4 is prevented during soldering and similar operations. Subsequently, characters 7 and the like are provided on the covering member 6 by silk sheet printing to provide information regarding the process (step 6).
However, the pitch of pins in such machines is often only about 1 mm. Thus, numerous soldering bridges can still be formed even when soldering is performed manually.
Such soldering bridges are discovered only when the power source of the machine is turned on after manufacturing is completed. Discovering soldering bridges at this time lowers production efficiency.
This problem can be solved by widening the space between electrode units in the pattern. However, widening the space between electrode units makes the circuit board too large.
SUMMARY OF THE INVENTION
Thus, it is an object of the invention to provide a printed circuit board, and a method of manufacturing the printed circuit board, wherein the formation of soldering bridges is prevented without making the printed circuit board large, even if the parts to be soldered are separated by extremely small pitches.
A printed circuit board in accordance with an embodiment of the invention includes an electrically insulated board. A plurality of patterns that include electrically conductive members are provided on the printed circuit board. Electrode units for electrical connection are provided at a tip section of the pattern. The electrode units are provided adjacent to each other and are separated by a space. Electrically insulated covering members cover the pattern except for the electrode units. Electrically insulated separation members are provided in the space between the electrode units.
A printed circuit board in accordance with another embodiment of the invention includes an electrically insulated board. A plurality of patterns that include electrically conductive members are provided on the board. Electrode units for electrical connection are provided at a tip section of the pattern. The electrode units are provided adjacent to each other and are separated by a space. Electrically insulated covering members cover the pattern except for the electrode units. The electrically insulated covering members cover the pattern in such manner that the space between adjacent electrode units at a boundary side of the covered units and the electrode units is larger than at a tip side of the electrode units. Electrically insulated separation members are provided in the space between the electrode units.
The separation members may be extended to the covering member, which are covered to widen the space between adjacent electrode units at the boundary side.
A method of manufacturing a printed circuit board in accordance with an embodiment of the invention includes providing a plurality of patterns that include electrically conductive members on an electrically insulated board. The method includes a step of providing electrode units for electrical connection at a tip section of the pattern. The electrode units are provided adjacent to each other and are separated by a space. The method includes a step of covering the pattern except for the electrode units. The method also includes a step of providing electrically insulated separation members in the space between adjacent electrode units.
A method of manufacturing a printed circuit board in accordance with another embodiment of the invention includes providing a plurality of patterns that include electrically conductive members on an electrically insulated board. The method includes a step of providing electrode units for electrical connection at a tip section of the pattern. The electrode units are provided adjacent to each other and are separated by a space. The method includes a step of covering the pattern except for the electrode units such that the space between adjacent electrode units at a boundary side of the covered units and the electrode units is larger than at a tip side of the electrode units. The method also includes a step of providing electrically insulated separation members in the space between adjacent electrode units.
In the method of manufacturing a printed circuit board, another step may be used to provide the separation members on the covering members, which are covered to widen the space between adjacent electrodes at the boundary side.
Moreover, the separation members may be silk to enable silk printing on the printed circuit board.
In accordance with the invention, the electrically insulated separation members are provided in the space between adjacent electrodes of the patterns which are provided on the printed circuit board. The separation members prevent solder from moving to adjacent electrode units, even when a large amount of solder is attached to the electrode units. Thus, the formation of soldering bridges between adjacent electrode is prevented. As a result, the yield of the production line is improved and the repair process in the production line is minimized.
The space at a boundary side of the covered units and electrode units is larger than the space at a tip side of adjacent electrode units which are provided on the board. Thus, the amount of solder at the boundary section, where solder tends to pool when soldering is performed, due to the movement of the soldering iron from the tip side towards the boundary side, can be reduced. As a result, soldering bridges are prevented from forming between adjacent electrode units.
The separation members may be formed of silk to enable silk printing on the printed circuit board. Thus, the thickness of the silk layer that is used as a separation member becomes larger than the thickness of the covering member layer. This ensures that solder is prevented from moving between adjacent electrode units. Moreover, the silk is provided as a separation member by a silk printing process which is performed during the normal manufacturing process of the printed circuit board. Thus, a separate step for providing the separation member is obviated, which reduces costs.
Further objects, details and advantages of the invention will be apparent from the following detailed description, when read in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a manufacturing process of a printed circuit board in accordance with an embodiment of the invention;
FIG. 2 is a top elevational view showing patterns on a printed circuit board in accordance with an embodiment of the invention;
FIG. 3 is top elevational view showing a silk printing sheet which is used to provide a covering member on a printed circuit board in accordance with an embodiment of the invention;
FIG. 4 is an enlarged top elevational view showing the location of electrode units after covering members are provided on a printed circuit board in accordance with an embodiment of the invention;
FIG. 5 is a top elevational view showing a silk printing sheet of a printed circuit board in accordance with an embodiment of the invention;
FIG. 6 is an enlarged top elevational view showing the location of electrode units in which silk is provided through silk printing after covering members are provided on the printed circuit board in accordance with an embodiment of the invention;
FIG. 7 is a sectional view taken along plane 7--7 of FIG. 6 in accordance with an embodiment of the invention; and
FIG. 8 is a sectional view showing another embodiment of the apparatus of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 shows patterns of a printed circuit board in accordance with an embodiment of the invention. Specifically, FIGS. 2 and 4 show adjacent electrode units 5A. FIG. 4 shows a covering member 6A provided on a covered section 60 having adjacent electrode units 5A. The covering member 6A is provided on the covered section 60 by using a printing sheet 8, which is shown in FIG. 3. The printing sheet 8 has a transfer pattern 8B that provides the covering member 6A on the covered section 60. The transfer pattern 8B is nontransferable at position 8A, i.e., the transfer pattern 8B does not transfer the covering member 6A at position 8A. Position 8A corresponds to a space 12 between adjacent electrode units 5A at a boundary section 5A2, between the adjacent electrode units 5A and the covering member 6A, is concave in shape.
In accordance with the present embodiment, each heat generating unit of a thermal head is soldered onto each adjacent electrode unit 5A, respectively. As a result, at the boundary section 5A2 between the adjacent electrode units 5A and the covering member 6A, the space between adjacent electrode units 5A is larger than at the tip section 5A1 of the electrode units 5A. Thus, the amount of solder which is pooled in the boundary section 5A2 is minimized. Solder is less likely to attach onto the covering member 6A than onto the electrode units 5A because the covering member 6A is made of resin. Thus, solder tends to pool at a position corresponding to the end of the movement of the solder iron. During soldering, the soldering iron is moved from the tip side towards the boundary section 5A2 side (extension side continuing to the pattern 4A). Generally, elements being soldered are extended toward the tip section 5A1 side. Therefore, the above described moving direction of the solder iron makes the soldering operation smooth since the elements do not interfere with the movement of the soldering iron. Thus, the fact that the space between adjacent electrode units 5A is larger at the boundary section 5A2 reduces the likelihood of solder bridges forming between adjacent electrode units 5A. However, the formation of solder bridges is not completely prevented by only this structure.
In accordance with the present embodiment, the formation of solder bridges is prevented by first covering with the covering member 6A and then performing printing of the separation member 9. The printing includes silk screen printing separation member 9 in the space 12 between electrode units 5A using a silk printing sheet 10. As shown in FIG. 5, the transfer pattern 10A is provided on the silk printing sheet 10 beforehand in order to print the separation member 9 onto each position corresponding to the space 12 between adjacent electrode units 5A.
Epoxy type resin is used as insulating material for both the separation member 9 and the covering member 6A.
Thus, as shown in FIG. 6, the separation member 9 is provided at each space 12 between adjacent electrode units 5A, and on the convex shaped section 6A1 of the covering member 6A which covers the boundary section 5A2. Thus, the movement of solder from one electrode unit 5A to another electrode unit 5A adjacent to the one is prevented, and solder bridges cannot be formed between adjacent electrode units 5A.
Specifically, as shown in FIG. 7, which is a sectional view taken along plane 7--7 of FIG. 6, the separation member 9 is provided on the convex shaped section 6A1 of the covering member 6A, which covers the boundary section 5A2 of the electrode unit 5A. This structure reliably prevents the movement of solder to adjacent electrode units 5A.
In accordance with the present embodiment, the thickness of the covering member 6A is about 8 μm, the thickness of the electrode unit 5A is about 35 μm and the thickness of the separation member 9 is about 15 μm. Alternatively, the thickness of the covering member 6A at the space 12 of boundary section 5A2 may become thicker than the thickness of the electrode unit 5A as shown in FIG. 8. By providing the separation member 9 with sufficient thickness in the space between the electrode units 5A in the manner described above, the movement of solder from one electrode unit 5A to another electrode unit 5A adjacent to the one and the formation of solder bridges between them are prevented.
The present embodiment describes a case in which the shape of the covering member 6A1 of the boundary section 5A2 between the electrode units 5A and the pattern 4A is made into a convex shape, and the separation member 9 is provided in the space 12 between adjacent electrode units 5A. However, this case is discussed for explanatory purposes only, and the formation of solder bridges may be prevented by only providing the separation member 9 in the space 12.
Additionally, as shown in FIGS. 4 and 6, the present embodiment describes a case in which the covering member 6A1 is formed into a triangular convex shape. However, the invention is not limited to this case. Specifically, other convex shapes are equally as effective in preventing the formation of solder bridges, such as a round convex shape or a square convex shape.
While this invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the preferred embodiments of the invention as set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims.
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A printed circuit board in accordance with the invention includes an electrically insulated board. A plurality of patterns include electrically conductive members are provided on the board and have electrode units for electrical connection. The electrode units are provided adjacent to each other and are separated at a tip section of the pattern. Electrically insulated covering members cover the pattern except for the electrode units. Electrically insulated separation members are provided in the space between the electrode units.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a Submission Under 35 U.S.C. §371 for U.S. National Stage Patent Application of International Application Number: PCT/NO2009/000196, filed May 26, 2009 entitled “ROLE BASED SYSTEM AND DEVICE FOR COMMAND AND CONTROL,” which claims priority to Norwegian Patent Application Serial No. 20082556, filed May 30, 2008, the entirety of both which are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
n/a
FIELD OF THE INVENTION
The present invention relates to a system and a device for wireless communication and more particularly to a communication system consisting of a central unit and portable team units with positioning capability and the ability to send and receive information between each other. For military and rescue operations such systems, or groups of such systems, are often called Command and Control Systems (abbreviated to CCS or C2S).
BACKGROUND OF THE INVENTION
Current portable wireless communication terminals for military and field use have the ability to communicate with other similar devices over a large area and have map systems that show an abundance of information that can be shared. They also have the ability to send audio messages to the other terminals in form of peer to peer voice messages like the similar “walkie-talkie” technology.
However there are situations where large complex systems with maps and audio communication are not favorable, in certain field situations there are advantages to having a communication terminal that can be operated simply and that does not show unnecessary information; there are also certain situations where it is an advantage to communicate via text messages and not through audio messages, like in areas with a high noise level e.g. during an emergency, or a catastrophe, or areas where there is an advantage to keep a low noise level e.g. in a military operation. In these situations it is crucial that the unit is easy to operate and that the information shared by the different terminals does not reach the wrong person(s). In these situations it is also favorable to have the ability to communicate with all the other team units. In certain situations like in a rescue operation or in a military operation it is also an advantage to assign the different units one or more roles that can be displayed to the other units, reflecting the unit's tasks. This role must be possible to change, both from the unit itself, or from units with a relevant role. E.g. a team leader can assign roles to its team members, but if the team leader is taken out of operation another unit must be able to take the role as team leader.
It is known from FFI Fakta (http://www.mil.no/multimedia/archive/00086/Faktark-NORMANS-KKI- — 86445a.pdf) that a system designated “Normans KKI” and “Normans ledelse” includes a unit (KKI) to be placed and integrated by wire on a soldier's dress in order to make information about positions of the soldier and designated team members show up on a display of the unit. The unit contains a digital magnetic compass and a GPS and also a simple message function enabling for example alarm messages. Passive sensors can be coupled to the unit. The “ledelse” unit is a handheld unit that shows the positions of all soldier units displayed on a digital map giving the leader an overview of his team. The “ledelse” unit is supplied with software for interactive planning with the units of the soldiers. Marching routes, way points or other battle related information can be put into the digital map. Also, active sensors can be coupled to the “ledelse” unit and information from passive sensors on the soldiers' units can be collected. The message functions of the “ledelse” units allow for sending and reception of maps, text, orders, alarms and positions.
The systems available at the present like the one in US 2006/0238331 A1 shows a communication unit mainly for military use that has a GPS based map interface displaying the location of other team units. This information is shared between the different team units by radio communication via a central unit that receives the information, organizes it and sends it back out to the different team units in the system in a strict hierarchy, using a master-slave configuration. The different team units can also receive audio messages either from the central unit or from each other. These team units have in addition to biosensors that monitors the pulse, temperature and blood pressure also abilities for iris scan of the user and a credit card chip for economic settlement.
Further it is known from U.S. Pat. No. 6,898,526 B2 a communication terminal system intended for hunters that has a GPS based map system and a radio communication device for communicating your position to a central unit, the central unit sends the location of the different team units to each team unit. The information is shown on a map interface with a compass bearing, the team unit then further communicates with the weapon in the form that it always knows where it is pointing and can stop the weapon from firing in the direction of other team units. This system does not have the ability to communicate any other information than the location information received from the GPS unit.
It is also known from U.S. Pat. No. 6,373,430 B1 a portable team unit with GPS and radio that communicates the location information from the GPS with one or more other equal team units. The location information is sent over the radio link to the other team units. This information is shown in a map interface so that everybody in the system can see where the others are by showing a unique identification tag for each team unit.
U.S. Pat. No. 6,456,938 B1 teaches a system for navigation at a golf course, having a screen for showing a map of the course. The system has messages, and can show distances and bearings. The units may communicate directly, but cannot relay messages, nor show other player's position.
US2005/0001720 A1 and US2008/096519 A1 both teach systems that tracks mobile terminals and where a unit can have a role as e.g. “leader”.
Neither of these documents have a solution to the problem of avoiding a third party from using a lost or compromised unit, or that a unit may be discovered, disturb other communications or use too much battery because it transmits with unnecessary high power.
SUMMARY OF THE INVENTION
The system of the present invention consists of control and team units. In a preferred embodiment there is one control unit, typically used by the team leader, and several team units that all have roles. The positions of all team members are indicated on the displays, and the units can communicate with data messages directly or relayed with one another. Communication to other teams or to a headquarters is in normal situations done from the control unit only using another tactical communication system. In a preferred embodiment, all communication is encrypted, using asymmetric encryption to distribute a key for symmetric encryption to be used for a period.
The Team and Control Units
The unit of the present invention is a small communication unit specifically developed for soldiers, first responders such as fire fighters and the like. It has integrated radio transmission and receiving means, compass and positioning utilities. The unit communicates with all other team members' units including a central unit usually with the team leader, giving the users a visual presentation of all team members' position. All units have been allocated particular roles within the team and their current role is also displayed on other team members' units. The unit includes means for sending and receiving various messages to and from other team members, alarms and information from both active and passive sensors available within the current team.
The control unit of the present invention can be similar to a general team unit, the only difference being that the control unit has a particular role set, such as “team leader”, and may have a particular symbol 511 , such as the pentagon shown in FIG. 5 . In a preferred embodiment the control unit is responsible for configuring the encryption for the team, i.e. to initiate distribution of the symmetric key to be used. The control unit thus has stored, or the user enters, the public keys for all team members, whereas the team units, or their users, only need to know the public key of the control unit. In a preferred embodiment, the control unit also has a screen with resolution suitable for displaying maps, and the positions of the team units can be shown overlaying the map. The control unit may also have a more powerful transceiver than a team unit, communication devices for sending and receiving information outside of the team, an improved GPS receiver, a display with better resolution, and a device for text input to compose message, rather than selecting predefined messages from the menu. All units are designed to be operational for more than 10 hours of constant use, using re-chargeable 3.3v batteries with 1 Ah.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of team unit.
FIG. 2 is a front view of a team unit with four buttons.
FIG. 3 is an example communication flow in a team, with team units, central unit and sensors.
FIG. 4 is an example message format.
FIG. 5 is an example team unit display with alarm and out of bounds area.
FIG. 6 is an example team unit display with waypoint.
FIG. 7 is an example team unit display with alarm message.
FIG. 8 is an example team unit display with bearing only.
FIG. 9 is an example team unit display on low resolution screen.
FIG. 10 : Alarm displays indicating acknowledgement needed.
FIG. 11 : An alternative embodiment of the team unit with six buttons.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a block diagram of a unit. A bus is used for communication between the various modules. In a preferred embodiment, several different buses are used for interconnecting the modules: Serial Peripheral Interface (SPI) is used between the microcontroller and memory. Philips I2C used between the microcontroller and the compass, UART [universal asynchronous receiver/transmitter] is used between the microcontroller and the other modules. There are positioning and compass modules for positioning information. In a preferred embodiment the positioning module cannot be set in stand-by power mode by commands on the communication bus, but rather by controlling the power to the module. When the positioning module is turned on, it will remember its former settings and start searching for satellites based on this information. The transceiver is used for data communication with other team members. The remote device controller is, for example, using Bluetooth or other suitable protocols for communication with sensors. The display shows the information, for example, on a screen, but could also be a head up visor or retinal display. The microcontroller runs the state machine and memory is used both by the microcontroller, but also for storing messages and for logging positioning and sensor information, so that the unit may function as a black box where information can be recovered in case the unit's movement and sensor readings need to be recovered. The local input device controller is handling the use of the buttons, but could also handle e.g. a touch screen or other input devices directly connected to the unit. Input devices such as a keyboard can also be connected to the remote device controller, unique e.g. Bluetooth. To allow for optimized power saving abilities, each module can be controlled individually by reducing power consumption (for instance by reducing power transmission) or being switched off.
FIG. 2 is an illustration of one embodiment of a team unit 200 . According to this embodiment, the team unit has a screen 210 for presenting information to the user, two buttons 220 for scrolling through user menu and two buttons 230 for navigating inwards or outwards in the menu structure. The unit is designed for use under stressful circumstances and in hard conditions, with a simple and logical interface.
The team unit 200 has a built in position receiver used to receive positioning signals and calculate the user's own position. Various positioning means could be used in the present invention, e.g. GPS, GALILEO, GLONASS, etc. In one embodiment, the position receiver is a GPS receiver, for instance the LEA-5 from uBlox, that also supports GALILEO. In order to ensure optimal positioning signal strength, the antenna is mounted on the highest point of the unit. In this embodiment, the unit can receive signals from up to 16 satellites at one time, ensuring optimized accuracy of positioning data. Like all other electronics in the unit, the positioning module is designed to work with minimum power consumption. The positioning unit is communicating with the team unit control chip and radio transmission means for sending its own position to all other team members.
In addition to the positioning module, the unit 200 also has a build in compass module. In one embodiment, the compass module is a digital magnetic compass module having 2 magnetometer sensors mounted perpendicular to each other. The two magnetic sensors register the magnetic field surrounding the two axes, representing the earth magnetic field if no other magnetic fields are present. While this particular compass module requires the unit to be held in a horizontal position when reading the information, other compass units may be used to better ensure reliable data at all times. The compass information is only treated when the unit is set to “compass information” mode.
The team unit can also be equipped with a short range radio device, like Bluetooth, for communicating with various sensors and the like. It could also be used to connect the team unit to other personal equipment, for instance personal radio communication or sound devices.
The core of the unit is a microcontroller, specifically designed to operate without the need of an operating system. This ensures better and safer operating status, and a better protection against Electro Magnetic Pulse (EMP) attacks. Internal memory is used for logic and communication control, while at the same time giving the ability to store information, like, for instance, messages, waypoints and positioning log.
In one embodiment of the invention, all data received from the positioning module as well as sensors connected to the unit are stored in the memory module. In order to optimize for detailed logging information or high performance (low power and memory consumption), the logging update information could be adjusted accordingly (e.g. every 10 seconds or every 1 minute). After completion of an assignment, the users' movement and data from the sensors can be reviewed and evaluated. The complete session can be replayed, and the team can evaluate their performance based on accurate historical information. For training sessions or preparations for important missions, this feature can improve the overall performance of the team, making them aware of their movements in relation to other team members as well as evaluate the importance of information given from the sensors. In specific cases, for instance if a fallen soldier has been identified at the battlefield, the logging information could help explain the course of events. Both information about his/her movement, and information from the sensors, could give valuable information.
In one embodiment, two memory chips are used, one for central storing and one for additional use if needed. The memory chips are responsible for storing messages received to the unit, predefined messages that can be sent to the master unit, and received waypoints and other status information. All memory chips and controllers are selected based on their low power consumption, reliability and number of connection options. In one embodiment, the micro controller uses 3.3 V with a clock frequency of 73,728 MHz for ensuring good output and to better comply with the frequencies used in serial communication.
In a preferred embodiment of the invention, the team unit is operating using a state machine running a continuous loop, thus it does not need any traditional operating system. The core of the software is a state machine, always deciding what to be displayed and which next states are legal. The compiled software from the implemented controllers and electronic devices are loaded into a flash memory, and is automatically loaded when the unit is turned on. The state machine is running through a continuous loop, and certain modules are in operation at all times. Such continuously operating modules are, for instance, checking for button inputs, sending and receiving positioning information, registering communication between installed hardware etc. Both external information, like pushing one of the four buttons, or internal information, for instance information from one of the implemented modules, are deciding the next state.
As a state machine without an operative system, the unit is robust, and will in case of an error condition restart and enter a valid state. This is achieved by having a counter that is reset in the main loop, called a “watch dog”, where reset is triggered if an error situation occurs. Error conditions can occur, for example, after the unit has been exposed to an Electro Magnetic Pulse (EMP).
For situations where it is necessary that information must be treated immediately, the system uses an interrupt message to stop the continuous loop. A bit flag is set to warn the system about an interrupt, and the information is treated accordingly. Such information could be input to turn off the button lock, GPS signal information or saving incoming data in the memory chip. When receiving positioning data, the data is validated using Cyclic Redundancy Check (CRC) to ensure that the data flow is not corrupted. The data received from the positioning unit, like current position, GPS clock and data, is then being analyzed and stored in the memory unit.
FIG. 3 shows a team with team units TU 1 to TU 4 , a control unit CU, three sensors S 1 -S 3 and two control units for other teams CUA and CUB. CU communicates with TU 1 and TU 2 . Data, e.g. positioning information, alarms and sensor readings from TU 3 and TU 4 is relayed by TU 2 . As all units in the team can both communicate directly and relay for other units, the position from TU 3 is sent via TU 2 to reach TU 4 . In order to stop propagation of messages in the team when using the relay function, a hop count flag can be set in the message header. For instance, the message is only allowed to be relayed three times, setting the maximum hop count to three. In that case, when a relay message is received the hop count flag is decremented by one, and if larger than one the message is relayed. If the hop count equals zero after being decremented, the message will not be relayed further. In an alternative embodiment, time information is used rather than hop count. A sensor can be connected to one or more units, as is shown for S 2 . In this preferred configuration of the system, only CU is allowed to communicate outside the team, and is here shown to communicate with the control units of two other teams, CUA and CUB.
In special situations or for saving battery power, it can be important to transmit with as low a power as possible. In a preferred embodiment the power transmitted varies between 10 and 500 mW, the latter giving a range of up to 6 km. In one mode of communication messages are normally sent as encrypted broadcast messages. FIG. 4 shows message formats, including how only parts of the message need to be encrypted. If messages are not acknowledged, then the transmission power could normally be adjusted up. However, to transmit with low power, it is possible to enter a communication mode, where other units are used as relay, as shown in FIG. 3 . The communication mode could be set from the control unit, e.g. by sending a message indicating threat level, or by particular alarm messages, such as a gas alarm. It is also possible to indicate the power level in the messages. In FIG. 4 is a message format shown that uses half a byte to indicate the power level that has been used for sending the message. Various schemes can then be used, e.g. starting to transmit with low power and stepping it up until a level is reached where the messages are acknowledged.
In the preferred embodiment, the protocol used for communication is based on low power 8-bits microcontrollers, and are specifically designed to be optimized for low bit rates, high flexibility and allowing for large variation in message size and radio transmission frequencies. In addition, the protocol is designed for carrier independent communication, meaning that the data can be sent independently from underlying network structure. The protocol has three main parts;
A generic data format encapsulating different types of messages An acknowledge message, used in the systems reliability mechanism Different types of messages
In the message protocol, predefined message types are implemented, also presented in table 1.
TABLE 1
Size
Acknowl-
Message
Content
(byte)
edgment
Note
Pos
Longitude,
9
No
The unit's own position
Latitude
Text
Text
0-245
Yes
Free text or predefined
message
BattStatus
Battery
2
No
Indicates battery status
status
for attached Smart
Battery
AmmoStatus
Ammunition
2
—
status
Casualty
Longitude,
9
Yes
Indicates casualty or
Report
Latitude
injury at a given
location
Contact
Longitude,
9
Yes
Indicates hostile
Report
Latitude
detection from a given
position
Waypoint
Longitude,
9
Yes
Stored waypoint
Latitude
Poll
Request for
2
No
Used for requesting
information
information from team
unit after a given
message type (e.g.
battery status or
position)
TeamPos
Longitude,
10
No
For relaying team units'
Latitude,
positions to units outside
Pos-age
of current team
In one embodiment of the invention, the following message types are implemented; “Pos”—for sending team unit position to all team members, “Text”—predefined messages from the team unit or composed messages from the central unit, “BattStatus”—information about power status of the unit, “AmmoStatus”—information about the user's ammunition status, “Casualty Report”—injury or damage in a certain position, “Contact report”—enemy contact from given position, “Waypoint”—stored waypoint, “Poll”—request for information (e.g. battery status, position etc.) and “TeamPos”—from central unit to other central units or above ranked units regarding current team position. Most of the messages include positioning information from the sender, and at the same time some messages require the respondents to acknowledge the reception of the messages with an “Ack” message. Although various specific messages have been presented here, the protocol is not limited to these message types only. Additional types can be added if needed.
FIG. 4 is illustrating one possible implementation of a message structure. The message could be an all-to-all message, for instance alarm message, a predefined message stored in the team unit, or various status messages. When sending a message from the team unit, the message header is first assembled from the following fields; sender address, size of the data field, destination address, acknowledge flag and sequence number. The header, together with predefined preamble and verification fields are used to calculate the header check sum. After assembling of the header, data fields are added and the check sum calculated. The message is then sent, and if the message requires an acknowledgement the message is queued until acknowledge is received from the recipients and then deleted from the message system. If no acknowledgment is required, the message is deleted immediately.
In one embodiment the messages are encrypted, using a common symmetric encryption method such as the Advanced Encryption Standard (AES). As the messages may be relayed by several units that need not read the content of the message, the header is unencrypted. The AES key can be distributed and changed using Public-key cryptography, where the private keys may be set in firmware for each unit, and the public keys of possible team units can be stored or exchanged when the units are distributed to the team. The units may also communicate without encryption or they can have a default AES key to be used when an AES key have not been distributed using the Public-key cryptography. If a particular unit is lost or compromised, a self destruct message could be sent. Such a message could for instance inform the device to initiate an erasure of all vital information, and only transmit messages (for instance position messages) unencrypted on an open channel. This prevents the lost unit from compromising the position and message information sent between the other team members, while at the same time being able to keep track of the lost unit. In another embodiment, only the remaining units could update their symmetric encryption key (AES key) and in that way avoid sending information to the compromised unit.
When receiving a message, the message header is first collected and the check sum is calculated and compared to the value in the header. If the check sum is not correct, the message is deleted. If the receiver identification is not identical to the header destination or the message is not a broadcast message, the message will be disregarded. If the message is an acknowledge message, the sequence number is read and the message is put in the out queue. If the message is a data message, it will be stored in the internal unit memory. If the message is an acknowledgement message, the acknowledge message is produced based on sender address, sequence number and status, and then returned to the sender either automatically or when the user acknowledge that the message has been read.
FIG. 4 shows different message formats. The topmost message format is a simple, unencrypted format. The middle message is the data part of a message for positioning used when a unit reports its position. In addition this part has fields for vital sensor information, such as heart rate. The message at the bottom of the figure is a message for encrypted communication, where, for example, positioning data as shown above, can be placed. The format allows several teams to operate on the same radio channels, as the messages have address fields indication destination team and unit (DestinationL). The SessionID field indicates which AES key is used for the following encrypted part, and thus a unit, normally a control unit, may belong to more than one team.
In FIG. 3 , an embodiment of the presented invention, the system comprises one central unit and one or more team units, with all-to-all or one-to-all communication. In addition, sensors can be connected to the units e.g. using short range radio transmission (i.e. Bluetooth technology), sharing specific environmental information or information about the user of the team unit (i.e. heart beat or body temperature). The sensors can be active, such as a laser measuring distance or a triggered camera, or passive such as a heart rate sensor or a gas detector. Sensors could be classified as passive or active. The passive sensors are sensors not relying on actions from a user in order to be active. They are monitoring specific features continuously, for instance bio sensors or gas detection units. Active sensors are sensors operated actively by a user, for instance a laser distance measurement device. All sensors could be operated by any user in the team, and the communication module in the unit makes it possible to transfer information from one sensor to all members of the team.
The central unit also has the ability to send messages to other central units in different teams or to a higher ranked unit (for instance a troop command post). The messages could be positioning information, text messages, alarms, pictures and other useful information, using a message structure and protocol similar to the one used in the present invention, or using another tactical communication system.
In order to show the information to the user, the unit is equipped with a small screen interface, for presenting information to the user having both text and simple graphics. The screen is designed with two back light sources for ease of use and security reasons, one with traditional light and one with infrared (IR) back light, the latter for use in combination with night vision equipment. In daylight, the display is reflecting available light, making it optimal for reading in sunlight. In order not to reveal the user's position, for instance to enemy forces, the display can be inverted in order to reduce the amount of light to be radiated. The display brightness is adjusted using pulse module signals, turning the diode lights on and off with a high frequency, e.g. a duty cycle of 1/250. Other methods for avoiding detection could be used, e.g. different pulsing of light source, fluorescent backlight or night vision.
FIGS. 5 and 6 shows the display of a team unit. The unit itself is displayed in the middle as a circle with role information 510 ; the role is here shown as G 1 , e.g. meaning first gunner. Another team unit is shown as G 2 , e.g. meaning second gunner. This team unit is displayed in red, indicating a gas alarm, from a sensor connected to this unit. As can be seen in FIGS. 7 and 10 , alarms can also be indicated as messages on the screen. FIG. 7 shows an alarm displayed as an overlay message. This alarm does not indicate the need for acknowledgement, as the alarms in FIG. 10 . All positioning information is shown in relation to its own position and orientation. The circle 520 is a presentation of the current range resolution, the current radius of the circle is presented at the lower right corner of the screen; 530 . Other team members' and sensors' positions are presented as small circles with information about the current role of the unit. There are many other ways of presenting bearing and distance information on the display, e.g. by use of vectors, waypoints, distance information for all team member and symbols. The scale of the display could also be dynamically changed, e.g. based on the distance to the furthest unit, and this new scale could be indicated by the distance.
FIG. 8 shows only the bearing to other units, and not the distance. This is useful, for example, if the team members are very close, or some members are far away. In this embodiment the lack of distance information is indicated by the radius of the distance indicating circle shown as 0 m and the circle is dashed. There are other ways of indicating that only bearing is displayed.
The possible roles can be predefined in a list in the menu, or they could be freely set, e.g. by entering text for predefined roles or defining new roles as the text is entered. A role serves several purposes: it may inform the other team members of duties and expected behavior, it may give certain rights to configure the system or send alarms, or it may indicate the use of specialized sensors. Examples of roles are: Machine Gunner, Gunner, Senior Fire Fighter, Auxiliary Firefighter, Medic and Rescue Worker. Roles can be changed and a unit may have more than one role. The roles could be changed on the unit in question or from the central unit, and there could be set of rules defining which changes are allowed.
The Central Unit is here shown as a black pentagon 511 . Additional geographical information concerning the surrounding area could also be sent to the team unit and presented in the display. Such information could for instance be “Out of bounds” areas 540 ; areas where the team members are specifically forbidden to enter (like mine fields etc.). When an alarm message is sent from one of the team units, all other team units are warned and the position of the unit sending the alarm is highlighted in the display (G 2 ). The display will always be oriented in the same direction as the team unit, and based on range and angle to the other team members, the user will always be able to determine the correct position of all team members. A line indicating the direction to North or a predefined direction on the Earth is also displayed ( 550 ), ensuring that the team member is appropriately oriented to the surrounding area.
A unit that has lost positioning information, e.g. from being inside a building, can be indicated on the team's displays with information on how long the unit has been without positioning information or how uncertain the position is. The assumed position can be estimated by dead reckoning, and the uncertainty can be graphically indicated, e.g. by blurring the unit on the display.
FIG. 9 shows a display for a low resolution, monochrome display. Battery level and GPS reception level is indicated. An envelope indicates new messages. A key indicates encrypted mode. Time is shown as 15:31. The distance to a waypoint is shown as 65 m and the R=50 m indicates the scale by giving the radius of the circle. The display is inverted, as not to radiate more light than needed. Other team members are indicated with O, 1 and D.
In one embodiment, the menu structure in the team unit is designed to be operated with four buttons. Two buttons are used for scrolling in the menu system, while the two others are used for selecting or deselecting the different alternatives. FIG. 10 shows additional menu structures, and how the user is able to navigation by using the four buttons available in the team unit. The menu system is designed to allow for quick access to specifically important messages, for instance enemy contact. These messages are referred to as set click messages. In one embodiment, the right button could be used for selecting predefined messages directly. One click gives the user an overview of the message menu, the next click selects predefined messages, the third click selects alarm messages and the fourth click sends an enemy contact alarm. In this way, the user is given the ability to select the message enemy contact without having to look at the unit, while at the same time minimize the chance of sending an alarm message unintentionally. In case of enemy contact, the user can select the alarm message by clicking rapidly four times on the right button, without having to take his/hers eyes of the enemy. Different menu structures and button combinations could be used to allow for more than the one set click message described here.
FIG. 10 shows alarms that overlays the display. The right hand indication of “forstått” (“understood” in Norwegian) is also an indication of which button to be used for a one-click acknowledgement of receipt.
In an alternative menu structure for a four-button team unit as of FIG. 2 , the scroll buttons 220 are used for scrolling in the choices as indicated and the right select button 230 is used for selecting.
FIG. 11 shows an embodiment of a team unit with six buttons. The two side buttons operates as a single input command; both buttons need to be pressed to activate. This gives in effect a five button unit, but with added confidence when using the fifth button, in that the two halves of the button are placed on adjacent sides of the unit. This button can e.g. be used for giving critical alarms such as enemy contact or reporting injuries.
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A system and device for enabling tracking and communication between units in a team, typically used for military or rescue operations. The system, known as Command and Control System, has a handheld central unit with a display for showing positions of team units and portable team units having GPS, compass and radio communication function for sending and receipt of positions and alarms and for receiving text messages, a display for showing own positions and bearings. The units have the ability to send data directly or relayed to each other. Each unit can be assigned one or more roles and can send or receive messages that instruct actions like, deletion of vital information or control of power consumption.
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BACKGROUND OF THE INVENTION
This invention relates to solenoids and more particularly to solenoids providing impact hammer type operation for use in industries such as matrix printing and signmaking. There has been an unsatisfied demand for higher and higher speeds in this type of equipment.
SUMMARY OF THE INVENTION
The primary object of the invention is to provide an impact hammer solenoid that follows external control signals at substantially higher speeds and at a longer stroke than prior art devices.
This is achieved by positively driving a plunger in both directions by magnetic force instead of using a return spring as in prior art devices. Two separate coils wound on separate bobbins are mounted at the ends of a cylindrical shell and are separated by a thick magnetic flux washer between the shell and plunger. This washer carries the flux for both coils, resulting in the plunger being driven in one direction when one coil is energized and in the opposite direction when the other coil is energized.
The invention also features long backstops at both ends of the shell, these backstops providing a space for a short plunger near the flux washer, the length of this plunger being about equal to or shorter than its diameter. The reduced mass allows the plunger to operate at high speeds. This speed is increased by anti-residual pads of non-magnetic material at both ends of the plunger. These pads absorb the shock and their resiliency provides a bounce starting the plunger in the opposite direction. The pads being non-magnetic also act as an air gap between the plunger and backstop which speeds the decay of the magnetic field. This further increases the possible operating frequency of the plunger.
Consistent operation of the solenoid is enhanced by accuracy in setting the plunger stroke. The invention includes a non-magnetic sleeve surrounding the plunger and serving as a spacer between the backstops.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevation partly in section of a solenoid embodying the invention.
FIG. 2 is a perspective view, with a portion broken away, showing the first step in the attachment of the solenoid plunger onto the push-pull rod.
FIG. 3 is a perspective view similar to FIG. 2 illustrating attachment of the solenoid plunger onto the push-pull rod.
FIG. 4 is a front view of the flux washer shown in FIG. 1.
FIG. 5 is an elevation of the drive end of the solenoid of FIG. 1.
FIG. 6 is a schematic wiring diagram.
FIG. 7 is a sectional view similar to FIG. 1 but showing an alternative bearing arrangement for the solenoid plunger.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2, reference character 1 indicates a cylindrical shell or frame of a magnetic core means which is closed at its right hand end by a disc 2 carrying an elongated circular drive end backstop 3 at its center. This backstop extends inwardly to a point near the center of shell 1. Disc 2 is also formed with a screw threaded mounting hub 4 on its outside for a purpose described below. The disc 2 is fastened to the shell 1 by external screw threads 5 which fit into internal screw threads at the end of the shell. Spanner wrench holes 6 are formed in disc 2 (FIG. 5) for tightening the disc in the shell.
The left hand end of the shell 1 is closed by disc 7 screw threaded into the shell. Disc 7 supports an elongated return end circular backstop 8 extending to a point near the center of the shell.
The ends of the backstops 3 and 8 are accurately spaced by a non-magnetic stainless steel sleeve 9 supported by a flux washer 10 at the center of shell 1. This flux washer engages the interior of shell 1 and is attached to the sleeve so that the sleeve properly locates the flux washer in the shell. In the exemplary construction, tabs 9a (FIG. 4) are bent outwardly from the sleeve and seat in an annular groove 10a along each round end surface of the washer; two tabs 9a are bent out from each end of the sleeve in this fashion and engage each end surface of the washer to firmly attach sleeve 9 to flux washer 10.
In the space between the ends of backstops 3 and 8 and inside of sleeve 9 is a short round solenoid plunger 11 carried by a hardened stainless steel push-pull rod 12. This rod extends through oversize holes 13 and 14 in backstops 3 and 8 and is supported by an elongated bearing 15 supported in the backstop 3 and hub 4 of disc 2. The bearing may be made of recognized bearing material such as 660 bearing bronze. The sleeve 9 is larger than the plunger providing an air space allowing free axial movement of the plunger. The push-pull rod 12 extends beyond the mounting hub 4 and is formed with an end having a radius 17 which does the work for the solenoid. Nut 16 is threaded onto hub 4 and can be adjusted to control the length of rod 12 that extends beyond the nut.
Plunger 11 is to be securely mounted on push-pull rod 12, and FIGS. 2 and 3 illustrate a presently-preferred construction for this purpose. Rod 12 is formed with a radiused groove 18, and plunger 11 is formed with a circumferential groove 19. Plunger 11 and rod 12 are placed in a suitable die, not shown, with the plunger located to surround groove 18 of the rod, following which pressure is applied axially against the plunger as shown by the arrows in FIG. 3 to swage the plunger onto the rod. Plunger 11 is of ductile metal, and part of the plunger flows into groove 18 of rod 12 while groove 19 closes either completely or partially (as shown) when pressure is applied, thereby mounting the plunger onto the rod.
Mounted over backstop 3 is a coil means 20 wound on a moulded bobbin 21 and having external leads 22 extending through a slot 23 formed in shell 1. An identical coil 24, also wound on a bobbin 21, is fitted over backstop 8 and has external leads 25 extending through slot 26 in shell 1. The current flow in coil 20 is opposite in direction to the current flow in coil 24 so as to cause a reversal of magnetic flux and thereby provide a more rapid change of the forces on push-pull rod 12 described next.
As shown in FIG. 4, the flux washer 10 is formed with a slot 27 to stop eddy currents. This flux washer, shell 1, backstops 3 and 8 and plunger 11 are preferably formed of silicon iron "A" or "B" FM grade annealed and thus carry magnetic flux. When coil 20 is energized a magnetic flux circuit is established through shell 1, backstop member 2-3, plunger 11, and flux washer 10 back to shell 1. This pulls the plunger and push-pull rod to the right in the direction of coil 20. Coil 20 is then de-energized and the plunger and rod are allowed to coast. When coil 24 is energized a magnetic flux circuit is established through shell 1, backstop member 7-8, plunger 11 and flux washer 10 back to shell 1. This pulls the plunger to the left in the direction of coil 24. Coil 24 is then de-energized and the plunger and rod are allowed to coast. It should be noted that flux washer 10 is in both magnetic flux circuits.
In use the coils are energized alternately, with an off time before the other coil is energized, as schematically shown in FIG. 6 at a high rate such as in the range of about 500 to 1,000 cycles per second, causing the plunger and rod to cycle at this high speed. The off time allows the rod to coast and permits a long stroke without burning up the coils or destroying components of the solenoid. For example, rod stroke lengths in the range of about 0.015" to 0.030" are possible with the solenoid of the present invention.
In the exemplary circuit means of FIG. 6, a control circuit 40, which may include, for example, a microprocessor or other logic circuit, is used to generate logic command signals 41a and 41b for selectively energizing the coil 20 and coil 24, respectively, The logic command signals 41a and 41b are amplified by buffer amplifiers 42a and 42b, with the output of buffer amplifier 42a on line 43a being applied to the coil 20 and the output of buffer amplifier 42b on line 43b being applied to coil 24. The buffer ampliers 42a and 42b provide both current gain and voltage level translation, having logic inputs compatible with the logic command signals 41a and 41b, and with high voltage, high current outputs suitable for driving the coils 20 and 24. Diodes 44a and 44b are connected in series with resistors 45a and 45b to form snubber networks for the inductive reverse voltage spike produced when the coils 20 and 24 are switched off, respectively. Specifically, the series combination of diode 44a and resistor 45a is connected in parallel with coil 20, while the series combination of diode 44b and resistor 45b is connected in parallel with coil 24. The number of turns and wire gauge used to form the coils 20 and 24 are selected for the desired speed and force of operation, as should be apparent to those skilled in the art. In a specific version of the circuit means of FIG. 6 for a signmaking machine, the logic command signals 41a and 41b were generated in an interleaved fashion to energize one coil for 550 microseconds, de-energize both coils for 500 microseconds, energize the other coil for 550 microseconds, and de-energize both coils for 500 microseconds; this provided high speed operation of coils 20 and 24 at an up/down cycle rate of approximately 500 cycles per second. In the exemplary embodiment, the drive amplifiers apply a voltage of +24 volts when energized, resulting in a self-inductance limited, exponential rise in coil current to a peak value of approximately 6 amps in approximately 550 microseconds. Peak coil current is therefore limited by the short "on" time with respect to the self-inductance of each coil 20 and 24, while the average coil current is limited by the relatively low (e.g. 25%) duty cycle for each individual coil 20 and 24.
An important part of the invention making this high speed possible are the anti-residual pads 28 at each end of the plunger 11. These pads may be formed of a thin tough resilient non-magnetic plastic film material or non-magnetic Belleville washers.. The preferred materials for plastic film pads are polyvinylidene chloride film such as that available from duPont under its registered trademark KYNAR and polyurethane films. Each pad 28 is in the form of a round washer-like element of plastic film having a central aperture through which the push-pull rod 12 is inserted; the pads are not fixed in place on either plunger 11 or rod 12. These pads are about 0.010" thick and have 3 functions as follows:
1. To absorb the impact of the plunger against the backstop.
2. To use their resiliency to "kick-off" the plunger in the reverse direction.
3. To provide the equivalent of an air gap between the plunger and backstop which speeds the decay of the magnetic field.
This high speed impacting requires periodic replacement of the anti-residual pads 28. To make this replacement easy, the end discs 2 and 7 are formed with external screw threads 5 mating with internal threads on the shell. Thus the solenoid may be quickly taken apart, pads replaced and reassembled.
This screw thread construction also provides for close control of the plunger stroke. When the backstops 3 and 8 are tightened against sleeve 9 the only variation in plunger stroke is in the tolerances of the lengths of the sleeve and the plunger and the thickness of the anti-residual pads. It is easy to hold the total variation in stroke within 0.006 inch.
FIG. 7 shows an alternative bearing arrangement. The parts are the same as in FIG. 1 except that bearing 15 is replaced by bearings 30 and 31 mounted in discs 2 and 7, respectively. Bearings 30 and 31 also can be of 660 bearing bronze.
From the foregoing it will be seen that the invention provides a new solenoid construction having an extremely high speed and relatively long stroke of operation. This is achieved in part by a short low mass plunger made possible by elongated backstops, by the use of a drive coil and a return coil separated by a thick flux washer, and by thin resilient non-magnetic pads on both sides of the plunger.
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A high-speed impact hammer type solenoid capable of operating at high speed such as 500 to 1000 strokes per second and with a relatively long stroke length. It is housed in a cylindrical shell and includes two separate coils and magnetic circuits operating on a single short plunger. The plunger is driven magnetically in both directions. The short plunger has reduced mass. This is made possible by elongated backstops extending through the coils to the plunger and by a flux washer extending from the shell to the plunger. Close control of the plunger stroke is achieved by a non-magnetic sleeve surrounding the plunger and spacing the backstops which are screw threaded into the shell. Resilient anti-residual pads on each side of the plunger absorb the impact of the plunger with the backstop, start the plunger in the opposite direction and speed up the decay of the magnetic field.
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This Application is a 35 U.S.C. §371 National Stage Entry of International Application No. PCT/FR2011/053166, filed Dec. 22, 2011 and claims priority to French Patent Application No. 10 61210, filed Dec. 23, 2010, both of which are incorporated by reference in their entirety herein.
BACKGROUND OF THE INVENTION
The present invention relates to a method for modifying a civil engineering structure through reinforced soil techniques, such as for a structure with reinforced fill.
The structures concerned by the invention can be of various uses such as traffic lanes, extend a constructible space, prevent damage, erosion, or fall of wall stones or rock walls, or create an esthetic material.
A reinforced soil structure generally combines a compacted fill, a facing, and reinforcements or stabilization elements connected to the facing. The stabilization elements are placed in the soil with a density dependent on the stresses that might be exerted on the structure, the thrust forces of the soil being reacted by the soil-reinforcements friction.
The facing is most often made up of prefabricated concrete elements, in the form of slabs or blocks, juxtaposed to cover the front face of the structure. There may be horizontal steps on this front face between different levels of the facing, when the structure has one or more terraces.
The stabilization elements placed in the fill are usually secured to the facing by mechanical connecting members that may take diverse forms. Once the structure is complete, the stabilization elements distributed through the fill transmit high loads, in some cases of up to several tons. Their connection to the facing needs to be robust in order to maintain the cohesion of the whole.
Although these reinforced soil structures are very robust and capable of good performance, it can sometimes be realized that it is necessary to carry out changes to the structure.
For example, a structure initially designed to support four traffic lanes may need to be modified in order to permit the placement of six traffic lanes.
It may also be the case that over time the facing is degraded due, for example, to an initially unintended use of the structure or because of a construction defect of the facing.
The concrete facing elements can undergo concrete pathologies. Among the concrete pathologies known by the person skilled in the art which can lead to swelling of the facing elements, examples include alkaline reactions occurring within the concrete or internal sulphate reactions.
The internal swelling of crystals can lead to cracking followed by progressive breakdown of the concrete composing the facing. This swelling can take place over several months or several years. However, it is not detectable at the time of the production of the structure and this swelling may also be accelerated by unfavorable weather conditions.
The facing elements of a reinforced soil structure play an important role in the stabilization of the structure. Moreover, these facing elements also play an important architectonic role.
In the case of irremediable pathologies or facing element degradation, it may sometimes be necessary to restore the mechanical role of the facing by carrying out a repair.
Currently, the repair solutions essentially consist in replacing damaged or degraded facing elements.
The methods that are currently known by the person skilled in the art generally comprise the steps of:
stabilizing the fill by injection of concrete behind the facing element, cutting the facing element, removing it fragment by fragment, and casting a new facing element in place or replacing the old facing element by a prefabricated element.
The replacement of facing elements one by one is a long, meticulous process, presenting risks. In particular, it is necessary for large size structures to arrange a preliminary stabilization, for instance by injection of grout or resin in the fill material behind the facing elements. In fact, there is a risk of rock slide or erosion during the operation of withdrawal of the facing elements.
Therefore, there is a need for a method permitting to repair and/or modify a reinforced soil structure that does not have the shortcomings of the methods according to the prior art.
SUMMARY OF THE INVENTION
The invention therefore provides a method for modifying a reinforced soil structure, said structure comprising:
a fill, a first facing including an outer face defining the front face of the structure, and at least one stabilization element connected to the first facing and extending in a reinforced area of the fill located behind the front face of the structure,
the modification method including the following steps of:
arranging a second facing along the outer face of the first facing, disconnecting the stabilization element from the first facing, connecting the stabilization element to the second facing.
Advantageously, the method according to the invention does not require removal of the facing elements. Therefore, the implementation of the method according to the invention does not present a risk of rock slide or erosion so that the operations are simplified and the safety is considerably improved.
Furthermore, a method according to the invention can include one or more of the following optional features, considered individually or in all the possible combinations:
disconnecting the stabilization element from the first facing is performed by opening from the outer face of said first facing, for example through sawing, percussion, or coring; the method further comprises a step of placing a geotextile joint on the outer face of the first facing; the method further comprises a step of placing a compressible material between the first and second facings; the method further comprises a step of mechanically tensioning the stabilization element once the stabilization element is disconnected from the first facing; the method further comprises a step of putting in place a maintenance system for the mechanical tension of the stabilization element before disconnecting the stabilization element from the first facing; the second facing has substantially the same height as the first facing; the second facing is placed against the first facing; the second facing is placed along the outer face of the first facing in order to define a volume to be filled, the method further comprising a step of introducing filling material into said volume; the second facing is placed along the outer face of the first facing in order to define a volume to be filled, the method further comprising the steps of:
introducing filling material into said volume, and compacting the filling material placed in said volume;
the first and second facings respectively comprise a first and a second assembly of prefabricated elements, the prefabricated elements of the first and second assemblies having substantially identical shapes and sizes and the prefabricated elements of the second assembly being placed according to a layout that is substantially identical to that of the prefabricated elements of the first facing; and/or the second facing includes a mesh to which the stabilization element is connected, the second facing element being then obtained by shotcrete.
The invention also relates to a reinforced soil structure modified through a method according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood after reading the following description, only given as an example and with reference being made to the attached drawings in which:
FIG. 1 is a schematic view in lateral section of a reinforced soil structure in the process of being built;
FIGS. 2 a to 2 d illustrate the placement of a second facing through a method according to a first embodiment of the invention;
FIGS. 3 a to 3 b illustrate the placement of a second facing by means of a method according to a second embodiment of the invention,
FIG. 4 is a schematic view in lateral section of a reinforced soil structure obtained by means of a method according to a third embodiment of the invention.
DESCRIPTION OF EMBODIMENTS
For clarity reasons, the different elements represented on the figure are not necessarily drawn to scale.
FIG. 1 illustrates a reinforced soil retaining wall. A compacted fill 1 in which stabilization elements 2 are distributed, is delimited on the front face of the structure by a first facing 3 formed by juxtaposing prefabricated elements 4 in the form of panels, and on the rear side by the soil 5 against which the retaining wall is erected.
In the example represented in FIG. 1 , the stabilization elements 2 are linear elements such as rolled steel reinforcing members or geotextile strips.
The stabilization elements 2 may comprise metallic or synthetic reinforcing members, for instance in the form of flexible strips extending in the horizontal planes behind the first facing 3 . These may in particular be reinforcement strips based on polyester fibers encased in polyethylene.
The stabilization elements 2 are anchored at the rear face of the facing elements 4 , for example using hollow wall anchors, embedded anchors, nails or metallic rings, or any other anchoring mean known by the person skilled in the art.
According to a first embodiment, the method according to the invention permits the modifying of a reinforced soil structure in the same way as represented on FIG. 2 a.
The method according to the invention may permit, for example, to enlarge the reinforced soil structure. This can present an interest, in particular if the reinforced soil structure support a roadway and it is desirable to enlarge this roadway.
This reinforced soil structure comprises a fill 1 , a first facing 3 comprising an outer face 8 defining the front face of the structure. The first facing is composed of an assembly of first facing elements 4 . The reinforced soil structure further comprises first stabilization elements 2 connected to the different first facing elements 4 and extending in a reinforced area of the fill 1 located behind the front face of the structure.
FIG. 2 a illustrates a first step of the method according to the invention. During this first step of the method, at least one of the stabilization elements 2 connected preferably to the lowest facing is disconnected. To achieve this disconnection there can, for example, be performed a coring of the facing element 4 from the front face of the structure where the stabilization element is connected. Once this coring is performed, it is possible to disconnect the stabilization element from the facing element 4 .
According to an alternative embodiment of the invention, tensioning may be applied on the stabilization element 4 using biasing members as disclosed in application FR 03 12083.
The method according to this first embodiment then comprises a step of placing a second facing illustrated on FIG. 2 b.
During this step of placing a second facing, an element 14 from the second facing is fitted along the outer face of the first facing 4 in order to define a volume to be filled 16 .
The method according to this first embodiment then comprised a step of filling illustrated on FIG. 2 c.
During this step of filling, filling material is introduced and progressively compacted in the volume 16 defined between the first facing element 4 and the second facing element 14 , until it reaches the level of the coring performed in the first facing element 4 .
The materials that can be used as filling material include the natural soils, treated or stabilized soils through the use of lime or hydraulic binder, recycling material such as recycled concrete, road milled materials, some residues from industrial combustion or solid waste, etc.
The method then comprises a step of placing a second stabilization element illustrated on FIG. 2 d.
During this step of placing a second stabilization element, a stabilization element 12 is installed on the fill previously introduced and compacted. This second stabilization element 12 is connected to the first stabilization element 2 , in order to form a new stabilization element comprising the first stabilization element 2 and the second stabilization element 12 connected one to the other.
The second stabilization element 12 may be connected to the first stabilization element 2 by any means of connection known by the person skilled in the art.
Filling material is then introduced over the second stabilization element 12 that has just been installed. This filling material is compacted as it is introduced.
The steps can be repeated as many times as needed if several stabilization element levels are placed in the reinforced soil structure to be modified.
According to an alternative embodiment of the invention, it is possible to apply tensioning on the new stabilization element comprising the first and second stabilization elements 2 and 12 after having connected the first and second stabilization elements one to the other. This tensioning can be achieved for example by using of a mechanical clamping device such as a tensioner.
According to a preferred alternative embodiment of the invention, the second facing element 14 has substantially the same shape and dimension as the first facing elements 4 .
Favorably, this simplifies the implementation of the method and this confers to the reinforced soil structure flexibility properties substantially identical to that of the initial structure.
According to a second embodiment of the invention, the method according to the invention permits to repair a reinforced soil structure in which the facing elements might have been damaged.
According to the second embodiment of the invention, it is possible to repair the whole reinforced soil structure such as illustrated on FIG. 3 a.
This reinforced soil structure comprises a fill 1 , a first facing 3 comprising an outer face 8 defining the front face of the structure. The first facing being composed of an assembly of the first facing elements 4 . The reinforced soil structure further comprises first stabilization elements 2 connected to the different first facing elements 4 and extending in a reinforced area of the fill 1 located behind the front face of the structure.
The method according to the invention permits to repair the structure without the need to replace the facing elements 4 one by one, hence avoiding a long, meticulous and risky process.
As illustrated in FIG. 3 a , the method according to the invention comprises a first step in which a first stabilization element 2 connected to a first facing element 4 is disconnected, preferably one of the first facing elements located at the base of the reinforced soil structure.
This disconnection can be performed, for example, through an opening from the outer face of the first facing element 4 , for example through sawing, percussion or coring. Following this disconnection, a second facing element 14 is placed along the outer face of the first facing element, preferably against the first facing element.
The first stabilization element 2 is then connected to the second facing element 14 as illustrated in FIG. 3 b.
According to an alternative embodiment of the invention, the stabilization element 2 may be maintained in tension after the step of coring or applied tensioning once connected to the second facing element 14 .
According to an alternative embodiment of the invention, the second facing element 14 may have anchoring means permitting to anchor the first stabilization element 2 to the second facing element 14 and mean of tensioning, such as a tensioner.
According to an alternative embodiment of the invention, it is possible, in order to avoid possible debris leak between the facing elements or fill leak between the joints, to put in place a complete geotextile joint on the front face of the structure to be repaired. This joint may also be placed in such a way as to cover the joint between the elements from the first facing; for example by sticking the layers of geotextile joints on the first facing.
According to an alternative embodiment of the invention, a compressible sheet, made of elastomer for example, may be placed between the first facing elements 4 and the second facing elements 14 . In this case, a tensioning of the stabilization elements 2 before their connection to the second facing element 14 is facilitated. This alternative embodiment of the invention is particularly favorable when the first facing elements 4 risk continuing degrading with time, by swelling in particular.
According to an alternative embodiment of the invention, the new facing elements are substantially identical to the old facing elements and placed in a way that is substantially identical in comparison to the latter. Favorably, the implementation of the method is found simplified and this confers to the reinforced soil structure flexibility properties that are substantially identical to those of the initial structure.
According to a third embodiment of the invention illustrated in FIG. 4 , it is conceivable to place against the front face 8 of the reinforced soil structure a second facing comprising a mesh 16 , metallic for example, wherein stabilization elements 2 will be connected. The second facing element is then formed using a shotcrete process on the mesh to which the stabilization elements 3 have previously been connected.
Shotcrete processes are well known to the person skilled in the art.
The invention does is not limited to the embodiments described and that have to be interpreted in a non-limiting manner, encompassing equivalent embodiments.
It is in particular possible to inverse the order of some steps of the particular embodiments described.
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The invention relates to a method for modifying a reinforced soil structure, said structure comprising: a fill, a first facing including an outer face defining the front face of the structure, and at least one stabilization element connected to the first facing and extending in a reinforced area of the fill located behind the front face of the structure, the modification method including the steps of arranging a second facing along the outer face of the first facing, disconnecting the stabilization element from the first facing, connecting the stabilization element to the second facing.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of application Ser. No. 10/559,474 filed Dec. 5, 2005, which is a National Stage Application of PCT/US04/17284 filed Jun. 3, 2004, and claims priority to and the benefit of U.S. Provisional Application Ser. No. 60/475,553 filed on Jun. 3, 2003. The entire disclosures of the prior applications are hereby incorporated by reference herein in their entirety.
TECHNICAL FIELD
[0002] The invention generally relates to methods of progenitor cell selection, propagation and use. More particularly, the invention relates to methods and compositions for producing a population of progenitor cells in vitro.
BACKGROUND OF THE INVENTION
[0003] Adult and embryonic stem cells are the subject of intense scientific interest because of their potential role in cell therapies. A potential stem cell source is the stem and progenitor cells that naturally reside in mature organs. However, the use of parenchymal progenitor cells has been hampered due to difficulties associated with their selective cultivation. For example, a major issue in the establishment of progenitor cell cultures from an adult pancreas or adult islet tissue is the overgrowth of contaminating non-parenchymal cell types and the continued presence of differentiation-committed cells.
[0004] Cultivation of islet progenitor cells is of particular interest as a potential treatment of insulin-dependent diabetes. Attempts have been made to cultivate islet cells derived from dissociated pancreatic tissue in serum-containing medium. However, the majority of serially propagated islet cell populations display only moderate proliferative capacity and retain differentiated properties. Fetal-derived progenitor cells, which are propagated with the aid of bovine brain extract, yield a cell population that gives rise to not only islet cells, but also acinar and ductal cells, and likely represents an earlier embryonic pancreatic progenitor as opposed to an islet precursor. Further, the method uses cells of embryonic origins which are naturally high in progenitor cell number, while it is more difficult to characterize and control progenitor cells in adult tissues. An islet cell population capable of producing insulin in vivo has been described. While the method allows for some degree of propagation of islet precursor cells, the cells require the concomitant co-propagation of stromal or “nurse” cells of a different tissue type such as the ductal cells, which represent the majority of the cells in the culture.
[0005] Alternative mechanical separation methods using, for example, cell markers, have been used to select for stem or progenitor cell populations. However, this artificial cell selection results only in a temporarily-enriched population of stem and progenitor cells.
[0006] None of the research has distinguished between the progenitor cells and their natural offspring, the transit amplifying cells, in the quest for obtaining a proliferating epithelial cell population containing a regenerative component. Hence, prior methods do not favor the maintenance of a progenitor cell pool over growth through transit amplification. Transit amplifying cells have a growth capacity that allows serial passages but they are naturally inhibitory to stem cell activation and continued expansion of progenitor cells (Hardin-Young et al. Current Neurovascular Research I, (2004); Parenteau, Encyclopedia of Animal and Plant Cell Technology, 365-78 (1999)). Failure to sustain progenitor cell activation and growth while controlling the generation and growth of transit amplifying cells or the survival of contaminating cell types has prevented the development and maintenance of substantially pure populations of adult progenitor cells. This difficulty has lead to variability experienced in the practice of human epithelial cell culture.
[0007] Thus, there exists a need for a method to produce a cell culture with the majority of the cells being parenchymal progenitor cells capable of prolonged expansion in vitro and organ regeneration with high fidelity in vivo. In addition, there exists a need for generating such cells from mature (adult and neonatal) tissue, especially parenchymal tissues.
SUMMARY OF THE INVENTION
[0008] The present invention provides methods for selecting and expanding progenitor cell populations derived from neonatal or adult parenchymal tissue. Cultured populations of progenitor cells of the invention are a readily available source of cells which, when implanted in vivo, are useful to augment, repair, restore, or replace a diseased, damaged, missing, or otherwise compromised tissue or organ.
[0009] Methods of the invention provide culture conditions that promote selection of true progenitor cells. According to the invention, cell culture conditions are selected that undermine more differentiated cells, thus releasing the inhibitory influence that more differentiated cells normally have on the growth of progenitor cells. The result is a culture that allows the formation of colonies of self-supporting, undifferentiated progenitor cells that constitute a majority of the cell culture. The invention contemplates any serum-free culture conditions that induce a stress response in the cell culture to suppress the propagation of more differentiated cells yet permit progenitor cell growth. Ideally, conditions are selected so that once a population of progenitor cells has been created, tissue-specific differentiation can be induced, either in vitro or in vivo.
[0010] Although any set of culture conditions that promote progenitor cell growth are contemplated, a preferred method for propagating progenitor cells includes a serum-free medium that induces apoptosis or necrosis in the differentiating and/or differentiated cells. Cells may be initially cultured in a stringent primary medium with low or no level of either calcium and/or growth factors in order to bias the culture toward progenitor cell activation and growth. After progenitor cell growth has been initiated and the progentitor cells expand to be the majority of the cell population, the cells are propagated in a secondary, minimal growth medium that can be less stringent than the primary medium. Finally, differentiation of the resulting progenitor cell culture may be promoted by addition of differentiating factors in a tertiary medium in the presence of specific growth factors.
[0011] Alternatively, progenitor cells are harvested for use prior to differentiation. Any medium composition that inhibits growth of differentiated cells is contemplated as a means for generating a progenitor cell population according to the invention. Reducing the concentration and/or effectiveness of growth factors is one way to accomplish this goal. Inhibiting cell adhesion is another way. However, other methods, such as reducing the concentration of certain ions that normally promote growth of differentiated cells, inhibiting cell adhesion, changing culture pH, and others are known in the art. Of course, a combination of any these individual techniques may be employed.
[0012] In a preferred embodiment, methods of the invention comprise providing in a serum-free medium a primary cell culture that includes a progenitor cell and at least one of a differentiating cell and a differentiated cell; inducing a stress response in the primary cell culture that permits the progenitor cell to replicate and suppresses propagation of the at least one of the differentiating cell and the differentiated cell; and identifying a population of progenitor cells resulting from the replication that constitutes a majority of cells in the primary cell culture. The methods may include steps of isolating progenitor cells from the primary cell culture and culturing the isolated progenitor cells to provide a secondary cell culture through no less than 5 serial passages. The secondary cell culture may be maintained in a defined culture medium including glutathione, e.g., between 0.01 to 10 mM glutathione.
[0013] The methods may further include a step of stimulating differentiation of the population of progenitor cells.
[0014] In a preferred embodiment, serial passages are performed when the secondary cell culture is between about 60% to 75% confluent. The primary cell culture or the secondary cell culture may be maintained in the presence of a matrix component such as collagen.
[0015] A preferred stress response induces apoptosis and/or necrosis in the cell culture. And a preferred primary medium has substantially no growth factor or organ extracts, and no or a low level of calcium. Any cell type may be used to generate the primary culture, but epithelial cells are preferred, e.g., pancreatic cells, liver cells, and epidermal cells. A preferred method produces a cell population comprising at least about 60%, 70%, or 80% progenitor cells by number. Cells are cultured for a time sufficient to generate a population of progenitor cells.
[0016] Stimulation of differentiated cells is accomplished in the culture by changing culture conditions to bias toward formation of differentiated cells, such as by increasing differentiating factors.
[0017] The invention provides a substantially pure population of mammalian progenitor cells propagated in vitro from non-fetal tissue.
[0018] Additional methods of the invention comprise preventing or treating diabetes by culturing islet progenitor cells in vitro according to methods described above; and transplanting the progenitor cells into a mammal.
[0019] The foregoing, and other features and advantages of the invention, as well as the invention itself, will be more fully understood from the description and drawings that follow.
BRIEF DESCRIPTION OF DRAWING
[0020] FIG. 1 illustrates cells related to parenchymal generation and a method of neogenesis using a progenitor cell pool.
[0021] The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. The advantages of the invention can be better understood by reference to the description taken in conjunction with the accompanying drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present invention provides, in part, methods for obtaining parenchymal progenitor cell population that is capable of self-sustained and prolonged expansion in vitro and organ regeneration in vivo and the resulting compositions. Methods comprise culturing primary cells in a culture medium that fails to support the maintenance of more differentiated cells, yet permits the growth and expansion of the underlying progenitor cell population. The result is a culture where progenitor cells constitute a majority, or preferably, a higher percentage, e.g., 60, 70, or 80 percent, of the cell population by number. In one embodiment, the cell culture is a substantially pure or homogenous population of progenitor cells. Once established, the progenitor cell population is propagated for multiple passages in defined conditions and, when desired, can be expanded for clinical treatment. One of the advantages of methods of the invention is that they provide a readily available source of progenitor cells that can be used in cell therapies.
[0023] Progenitor cells of the invention are derived from any organ or tissue containing parenchymal cells capable of regeneration including but not limited to, a cell population derived from pancreas, liver, gut, heart, kidney, cornea, skin, retina, inner ear, skeletal muscle, brain, or glands. In a preferred embodiment, the population of progenitor cells gives rise to cells of a specific parenchymal lineage, e.g. pancreatic islet endocrine lineage, liver hepatocyte cell lineage, or epidermal cell lineage.
[0024] Referring to FIG. 1 , to achieve neogenesis, i.e., de novo generation of functional tissue, methods of the present invention focus on the propagation and activation of a progenitor cell population in vitro. In one embodiment, a primary cell culture derived from an organ, e.g., the pancreas, contains multiple cell types. Resident stem cells 10 are slow-cycling cells that give rise to progenitor cells 20 . Progenitor cells 20 are minimally differentiated cells and make up the proliferating cell compartment responsible for organ regeneration. The stem cells 10 , which are slow-cycling, are distinct from the progenitor cell compartment and the transit amplifying cells 30 based on developmental studies, gene expression and apparent regulation by transcription factors. The progenitor cells 20 , once activated, generate transit amplifying cells 30 , which, in turn, lead to parenchymal cells 40 . The transit amplifying cells 30 are lineage committed, differentiating cells, and exhibit limited replication. The parenchymal cells 40 are maximally differentiated functional cells.
[0025] According to one aspect of the present invention, a substantially pure or homogeneous population of progenitor cells can be cultivated outside the body, i.e., in vitro, without relying on cells from non-parenchymal tissues such as stromal, connective, or support tissues. In other words, the progenitor cells of the present invention are able to achieve self-sustained propagation from cells of its own tissue type. According to another aspect of the present invention, such a population of progenitor cells can be selected by controlling the condition of the cell culture to eliminate or at least inhibit more differentiated cells, including differentiating cells and differentiated cells. An advantage of such a methodology is that a progenitor is identified more by its behavior and the outcome of such behavior than by any marker it might express at any given time or location. Another advantage is that known mechanisms for regulating cell cycles, including those pertaining to apoptosis and necrosis, can be used to achieve the goal of the invention.
[0026] In a preferred embodiment, a population of substantially pure epithelial progenitor cells is produced in vitro by culturing a primary cell culture of epithelial cells in a primary culture medium that induces a stress response in the cells which depletes mature, differentiated parenchymal cells and/or differentiating transit amplifying cells. This response alters the dynamics of cell signaling in the culture to permit the progenitor cells to replicate and propagate. The stress response kills the more differentiated cells such that the resulting cell population is substantially free of differentiated or differentiating cells, and contaminating cells from other tissue types, e.g., stromal, fibroblast cells. While it is not yet certain, suppression of more differentiated cells may silence cell-to-cell signaling that inhibits the replication of progenitor cells and/or possibly provide signaling to activate progenitor proliferation. As a result, the progenitor cells propagate without any type of “feeder” or “nurse” cells from other tissue types.
[0027] There are various other ways to monitor the stress response besides visual observation. For example, the expression of a heat shock protein or an acute phase reactant gene can be measured as an indicator of the stress response.
[0028] One way to identify a pre-confluent colony of progenitor cells is to determine whether the primary culture cells are undergoing active mitosis. Other ways include observing the cells under the microscope; or adding 5-bromo-deoxyuridine (BrdU), a thymidine analog, to the cell culture and detecting the incorporation of the BrdU into the cells using a monoclonal anti-BrdU antibody.
[0029] After a pre-confluent colony of progenitor cells is identified in the primary culture, it can be separated and used to establish a secondary cell culture comprising substantially homogeneous progenitor cells. The secondary cell culture may use the same type of culture medium as the primary culture, or use a medium that is less stringent. The secondary cell culture maintains the progenitor cells through multiple passages, and the progenitor cells retain the ability to differentiate or undergo neogenesis. In one embodiment, the progenitor cells undergo no less than five passages.
[0030] The present invention may further include steps to activate the progenitor cells to become differentiating cells, e.g., transit amplifying cells, and/or differentiated cells, e.g., parenchymal cells. The progenitor cells and/or their differentiating and/or differentiated offspring may be used in therapeutic applications, e.g., by implantation.
[0031] Throughout the description, where compositions are described as having, including, or comprising specific components, or where processes are described as having, including, or comprising specific process steps, it is contemplated that compositions of the present invention also consist essentially or, or consist of, the recited components, and that the processes of the present invention also consist essentially of, or consist of, the recited processing steps.
[0032] It should be understood that the order of steps or order for performing certain actions is immaterial so long as the invention remains operable. Moreover, two or more steps or actions may be conducted simultaneously.
[0033] Primary Cell Culture
[0034] The primary cell culture is designed to induce a stress response in differentiating and differentiated cells including contaminating cells of other tissue types, but to permit progenitor cells to propagate. It is believed that once the differentiating and differentiated cell population becomes depleted, the progenitor cells become activated, enter the cell cycle and start dividing with increasing rapidity. The stress response that initiates this selection process for the progenitor cells may be induced through a variety of means, for example, by inducing the apoptosis and/or necrosis of these cells. In one embodiment, the primary culture medium is chemically defined. “Chemically defined” means that the culture medium essentially contains no or substantially no serum or organ extracts. In certain embodiments, the medium contains a low level or is substantially free of growth factors. If a growth factor is present, it is preferably less than about 10 ng/ml, more preferably less than about 5 ng/ml, e.g., about 1 ng/ml. In one embodiment, the medium contains cAMP elevating agents, such as cholera toxin and foreskolin, preferably at a concentration of 9 ng/ml) to support the activation and outgrowth of the progenitor cells.
[0035] The primary culture medium may be designed to inhibit cell-cell adhesion. For example, the medium may contain nitric oxide which is known to inhibit cell adhesion and to disrupt cell-matrix interaction. Alternatively or in addition, tumor necrosis factor-alpha (TNF-α), interleukin 1-beta (IL1-(β), and interferon-gamma (IFN-γ) can be added to stimulate nitric oxide-induced apoptosis. The cells also may be cultured in diluted hydrocolloid, dextran, and the like, to disrupt cell adhesion and to disfavor the survival of more differentiated cells.
[0036] In some embodiments, the medium contains a low level of or no calcium. If calcium is present in the culture medium, the concentration of calcium is preferably less than about 1 mM, e.g., between about 0.001 to about 0.9 mM. In one example, the calcium concentration is between about 0.01 to about 0.5 mM, and in another example, at about 0.08 mM. While not wishing to be bound by theory, the low calcium environment is thought to limit the cell-to-cell contact that is necessary for the interaction and maintenance of the more differentiated cells. A low calcium environment combined with the chemically-defined culture medium and minimal concentration of growth factors causes the differentiated cells to divide more slowly, eventually causing those cells to undergo apoptosis resulting in a population of progenitor cells within the culture.
[0037] Many apoptosis or necrosis-related pathways are known in the art. The primary culture medium can be designed to initiate or enhance such pathways. Pathways that down-regulate such stresses can be deactivated—for example, protein kinases that inhibit apoptosis can be blocked. Many of these pathways are cooperative and can be used in combinations. Examples of such signaling pathways include the caspase pathways, the Bcl-2 pathways, and the interleukin-10 pathway.
[0038] The caspase pathway involves nuclear factor kappa B (NF-κB) which is a transcription factor that, once translocated to the nucleus, activates transcription of various genes including those affecting the onset of cell death. Ligands, antigens, antibodies, growth factors, cytokines, lymphokines, chemokines, cofactors, hormone and other factors that regulate NF-κB, such as tumor necrosis factor (TNF) can be added to the culture medium to kill the differentiating and/or differentiated cells through the caspase, Bcl-2, and other pathways. Such factors include TNF-α, TNF-like weak inducers of apoptosis (TWEAK), TNF-related apoptosis-inducing ligands (TRAIL), interleukins (IL) (e.g., IL 10), Fas ligands, Apoptosis inducing protein ligands (e.g., APO-3L and 2L), transforming growth factor beta (TGF-β), endotoxins (e.g., lipopolysaccharide), regulated-upon-activation normal T-cell expressed and secreted (RANTES), interferons (e.g., IFN-γ), oxadaic acid (a serine/threonine protein-phosphatase inhibitor) and so on.
[0039] Examples of apoptosis-inhibiting signaling pathways that can be disrupted to disfavor the survival of more differentiated cells include the AKT-mediated signaling pathway and those activated by other so-called “survival kinases” such as IKK, erk, Raf-1. Possible ways to interfere with the AKT signaling pathway include use of siRNA, growth factors such as those produced by autocrine/paracrine, and/or antibodies to block the receptor tyrosine kinase AKT. Alternatively, elimination of growth factors that could induce this pathway using a stringent, defined medium may lead to similar results. Another example of disrupting apoptosis-inhibiting signals includes deactivation of heat shock protein 70 .
[0040] Other environmental factors such as heat, radiation, humidity, and pH also can lead the desired stress response in the cell culture. For example, ultraviolet radiation may induce cell death in more differentiated cells.
[0041] Secondary Cell Culture
[0042] The secondary cell culture typically comprises progenitor cells selected from the primary cell culture by virtue of their ability to thrive in the stressed conditions. The secondary cell culture maintains the progenitor cells so that they maintain the potential to differentiate or under neogenesis without actual differentiation. The ability of a population of progenitor cells to endure prolonged propagation through serial passage brings about another advantage of the present invention, which is to ability to amass a sufficient amount of progenitor cells for neogenesis and other applications.
[0043] The secondary cell culture may use the same type of medium as the primary culture as it continues to suppress differentiation of the progenitor cells. Alternatively, the secondary culture medium may be less stringent. Some limited amount of growth factors may be added to the base medium since the culture initially is substantial free of more differentiated cells. Some non-essential growth factors can be used sparingly or intermittently in the secondary culture medium. Examples of such growth factors include epidermal growth factor (EGF), transforming growth factor alpha (TGF-α), keratinocyte growth factor (KGF) and basic fibroblast growth factor.
[0044] Further Regulation
[0045] Cells harvested from a primary or secondary culture can be further regulated. In certain embodiments, progenitor cells are induced to differentiate progressively into various stages as described earlier with reference to FIG. 1 . A tertiary medium may be prepared with differentiating factors such as a higher level of calcium, serum and/or TGF-β. The medium may also include dexamethasone and cyclic adenosine monophosphate (cAMP) elevating agents, and other factors known to promote and sustain the growth of differentiating cells. Cell differentiation may also be promoted by addition of extracellular matrix, hydrogel or hydrocolloid substances or polymers that can assist the formation of cellular complexes. Such cells are applied in various therapies.
EXAMPLES
[0046] The following examples are provided to illustrate the principle of the present invention and should not be interpreted in any way as limiting the scope of the claims. Those skilled in the art will recognize that various modifications can be made without departing from the spirit and scope of the present invention.
Example 1
[0047] Culturing Conditions
[0048] Progenitor cells derived from human tissue are established by enzymatically dissociating the tissue of interest or mincing to form 1-2 mm 2 tissue explants. If enzymatic digestion is used, enzymes such as collagenase, hyaluronidase, dispase, pronase, trypsin, elastase and chymotrypsin are preferred. Numerous methods of preparing a primary cell culture are known in the art.
[0049] Cultures are initiated by flattening and spreading a heterogeneous cell population onto a tissue culture substrate, such as a plate coated with Type I collagen. Typically, the majority of cells exhibit a large, spread epitheliod to fibroblastic appearance. The cells are then cultured in a chemically-defined culture medium that contains little or no calcium and very little or no growth factors. By chemically-defined conditions it is meant that the culture medium contains essentially no serum or organ extracts. If calcium is present in the culture medium, the concentration of calcium is preferably less than about 1 mM, e.g., between about 0.001 to about 0.9 mM. In another example, the calcium concentration is about 0.08 mM. If growth factor is present, its concentration is less than about 10 ng/ml, and preferably less than about 5 ng/ml, e.g., at about 1 ng/ml.
[0050] Single parenchymal progenitor cells and colonies of parenchymal progenitor cells are identified within the first 10 days. Usually, the colonies are visually distinct from other cells. Unlike most cells, the parenchymal progenitor cells remain small, rounded or hexagonal in shape. The progenitor cells are typically less than about 15 microns and have a dense appearance. Those cells are refractory and are readily-identified using phase-contrast microscopy. Moreover, the parenchymal progenitor cells can be identified by their active mitosis. Typically, colonies of parenchymal progenitor cells increase in number to become the predominant population in the primary culture within about 14 days. The cells are harvested by trypsinization when the loosely formed colonies and small dividing cells occupy about 50-70% of the cell culture surface. In one embodiment, the progenitor cells occupy about 80% of the cell culture surface.
[0051] The resulting progenitor population in a secondary culture is characterized as having a small size, a plating efficiency of about 40% or greater upon passage, and rapid cell division of about 36 hours or less. The progenitor cells are passaged for at least about 5 passages and can extend to about 13 passages, or more, depending on the split ratios used during passage. The cells typically achieve about 10 population doublings or greater. Cells maintain characteristics of tissue-specific progenitor cells, such as expression of lineage specific genes and genes developmentally associated with progenitor cells.
[0052] The progenitor cells have the ability to exhibit organotypic differentiation upon changing the culture conditions to an environment, i.e., a tertiary culture medium, that may contain factors that promote and/or support development and growth of differentiating cells. Examples of such factors include hydrocortisone, TGF-β, hepatocyte growth factor, or other factors that have been identified as effective in regulating embryonic organogenesis. Examples of other environmental conditions that can be introduced to the tertiary culture include the addition of an extracellular matrix to promote cluster formation or three-dimensional culture, the addition of calcium at a concentration greater than about 1.0 mM, or any method which allows cell-cell adhesion to occur and tissue architecture to develop. Any of these factors and conditions may be used together or in sequence to advance organogenesis depending on the tissue type.
[0053] The selection of a population of pancreatic islet progenitor cells is described below. However, that example is not intended to be limiting and progenitor cells can be derived from any organ or tissue containing parenchymal cells capable of regeneration such as the liver, gut, heart, cornea, skin, retina, inner ear, skeletal muscle, brain, or glands.
Example 2
[0054] Pancreatic Islet Cells
[0055] The endocrine progenitor cells are derived from either whole neonatal pancreas or isolated adult pancreatic islets. The cells are then cultured under stringent conditions to impose a stress condition on the cell culture in order to select for growth of an endocrine progenitor cell population. Once established, this population is propagated for multiple passages undifferentiated and thereby expanded for clinical treatment of insulin dependent diabetes.
[0056] The stress-inducing culture medium of the invention allows for the establishment of primary cultures and facilitates the identification of a subpopulation of cells from these primary cultures that can then be serially passaged, thus providing for an expanded number of cells that could have therapeutic value. Preferably, the stress-inducing culture medium consists of a chemically defined medium without serum or growth factors. Cells grown from the pancreatic or islet tissue using this medium and culture methodology show a predominantly epithelial-like morphology and express cytokeratin markers characteristic of epithelial cells.
[0057] As the cells are expanded in culture, they are characterized by expression of markers associated with pancreatic progenitor cells, such as PDX 1 . The homeodomain protein PDX1 is required at an early stage in pancreas development ( Nature Genetics 15:106-110 (1997); Development 122:1409-1416 (1996)). As differentiated endocrine cells appear, they separate from the epithelium and migrate into the adjacent mesenchyme where they cluster. PDX1 is later required for maintaining the hormone-producing phenotype of the β-cell by positively regulating insulin and islet amyloid polypeptide expression and repressing glucagon expression ( Genes Dev 12:1763-1768 (1998)). PDX-1 is also required to regulate GLUT2 expression in β-cells suggesting an important role in maintaining normal β-cell homeostasis.
[0058] Neurogenin-3, a member of the mammalian neurogenin gene family, has been established as a proendocrine gene (See Proc Natl Acad Sci USA 97: 1607-11 (2000); Curr Opin Genet Dev 9:295-300 (1999)) and is considered a marker of islet progenitor cells during development ( Development 129: 2447-57 (2002)). The progenitor cell characteristic of the islet-derived cell population expresses neurogenin-3.
[0059] The endocrine progenitor cells may be induced to differentiate using chemical or physical means, such as by supplementing the culture medium with an agent that promotes differentiation to insulin-producing beta cells or by inducing morphological changes such as cell cluster formation in the presence of extracellular matrix. The cells may also be induced to differentiate as a result of implantation into a permissive environment. For example, in vivo differentiation may be seen upon implantation under the kidney capsule, subcutaneously, or in the submucosal space of the small intestine.
Example 3
[0060] Culture Medium
[0061] A stringent, stress-inducing culture medium used for the primary culture contains no or essentially no serum or organ extracts.
[0062] A primary culture medium of the invention is provided with a nutrient base, which may or may not be further supplemented with other components. The nutrient base may include inorganic salts, glucose, amino acids and vitamins, and other basic media components. Examples include Dulbecco's Modified Eagle's Medium (DMEM); Minimal Essential Medium (MEM); M199; RPMI 1640; Iscove's Modified Dulbecco's Medium (EDMEM); Ham's F12, Ham's F-10, NCTC 109 and NCTC 135. A preferred base medium of the invention includes a nutrient base of either calcium-free or low calcium DMEM without glucose, magnesium or sodium pyruvate and with L-glutamine at 4.0 mM, and Ham's F-12 with 5 mM glucose in a 3-to-1 ratio. The final glucose concentration of the base is adjusted to preferably about 5 mM. The base medium is supplemented with one or more of the following components known to the skilled artisan in animal cell culture: insulin or an insulin-like growth factor; transferrin or ferrous ion; triiodothyronine or thyroxin; ethanolamine and/or o-phosphoryl-ethanolamine, strontium chloride, sodium pyruvate, selenium, non-essential amino acids, a protease inhibitor (e.g., aprotinin or soybean trypsin inhibitor (SBTI)) and glucose.
[0063] In one example, no growth factor is added to the medium. In another example, the base medium is further supplemented with components such as non-essential amino acids, growth factors and hormones. For example, TGF-β is added as an apoptogen for promoting apoptosis of differentiated liver cells or TNFα is added as an apoptogen of differentiated islet, liver and epidermal cells. Defined culture media which can be useful in the present invention are described in U.S. Pat. No. 5,712,163 to Parenteau and is incorporated herein by reference.
[0064] Titration experiments can be used to determine the appropriate concentrations for the supplements, as known by one skilled in the art. Examples of preferred concentrations are provided as follows:
[0065] A preferred concentration of insulin in the secondary medium is 5.0 μg/ml. Proinsulin, insulin-like growth factors such as IGF-1 or II may be substituted for insulin. Insulin-like growth factor as used herein means compositions which are structurally similar to insulin and stimulate the insulin-like growth factor receptors.
[0066] Preferably, ferrous ion is supplied by transferrin in the secondary medium at a concentration of from about 0.05 to about 50 μg/ml, a preferred concentration being about 5 μg/ml.
[0067] Triiodothyronine is added to maintain rates of cell metabolism. It is preferably present at a concentration of from about 2 to about 200 pM, more preferably at about 20 pM.
[0068] Either or both ethanolamine and o-phosphoryl-ethanolamine may be used in the practice of the present invention. Both are phospholipids that function as precursors in the inositol pathway and in fatty acid metabolism. Supplementation of lipids that are normally found in serum may be necessary in a serum-free medium. Either or both ethanolamine and o-phosphoryl-ethanolamine are provided to the media at a concentration range of preferably between about 10 −6 M to about 10 −2 M, more preferably between about 10 −4 M.
[0069] Selenium may be used at a concentration between about 10 −9 M to about 10 −7 M, preferably at about 5×10 −8 M. And amino acid L-glutamine or its substitute may be used at a concentration between about 1 mM to about 10 mM, preferably at about 6 mM.
[0070] When preparing the secondary medium for serial passage of progenitor cells, other components may be added to the media, depending upon, e.g., the particular cell being cultured, including but not limited to, epidermal growth factor (EGF), transforming growth factor alpha (TNF-α), keratinocyte growth factor (KGF), and basic fibroblast growth factor (bFGF). EGF as an optional component in a secondary medium may be used at a concentration as low as 1 ng/ml.
[0071] A preferred embodiment of the secondary medium includes: a base 3:1 mixture of DMEM (no glucose, no calcium and 4 mM L-glutamine) and Ham's F-12 medium supplemented with the following components to achieve the final concentration indicated for each component: 6 mM L-glutamine (or equivalent), 1 ng/ml EGF, 1×10 −4 M ethanolamine, 1×10 −4 M o-phosphorylethanolamine, 5 μg/ml insulin, 5 μg/ml transferrin, 20 pm triiodothyronine, 6.78 ng/ml selenium, 24.4 μg/ml adenine, 1 mM strontium chloride, 100 mM sodium pyruvate, 10 mM non-essential amino acids, and 5 mM glucose.
[0072] While the cell population propagated according to the invention comprises a pool of progenitor cells at one stage, further commitment to differentiation and organ development may be induced. A tertiary medium allows the progenitor cells to generate a majority of transit amplifying cells and advance organogenesis when desired. A preferred embodiment of the medium for the generation of transit amplifying cells includes a base mixture of 1:1 DMEM (no glucose, no calcium and 4 mM L-glutamine) and Ham's F-12 medium supplemented with the following components to achieve the final concentration indicated for each component: 6 mM L-glutamine (or equivalent), 10 ng/ml EGF or HGF or both (depending on cell type), 1×10 −4 M ethanolamine, 1×10 −4 M o-phosphorylethanolamine, 5 μg/ml insulin, 5 μg/ml transferrin, 20 pm triiodothyronine, 6.78 ng/ml selenium, 24.4 μg/ml adenine, 100 mM sodium pyruvate, 2×10 −9 progesterone, 1.1 μM hydrocortisone, 0.08 mM calcium chloride and 9 ng/mL forskolin.
[0073] Progenitor cells may be plated at a moderate density of between 1,000 to 5,000 cells per cm 2 in this medium on a collagen-coated plastic surface and cultured for at least one passage. The cell population may be used as is or further differentiation may be initiated. Where further differentiation is desired, the cells are transferred to conditions where forskolin is removed from the tertiary medium and the calcium concentration is increased, e.g., to about 1.88 mM. Other changes to the culture environment also may be included at this time, e.g., addition of an extracellular matrix component. Some of the changes in the environmental condition depend on the tissue type, e.g. epidermal cells may be cultured at an air-liquid interface, islet cells may be cultured in a matrix condition that promotes cluster formation, and hepatocyte cells may be cultured in a 3-dimensional substrate that promotes cord formation.
[0074] A typical way of preparing media useful for the present invention is set forth below. However, components of the present invention may be prepared using other conventional methodology with or without substitution in certain components with an analogue or functional equivalent. Also, concentrations for the supplements may be optimized for cells derived from different species and cell lines from different organisms due to factors such as age, size and health. Titration experiments can be performed with varying concentrations of a component to arrive at the optimal concentration for that component.
[0075] The medium, whether primary, secondary or tertiary, is prepared under sterile conditions, starting with base medium and components that are bought or rendered sterile through conventional procedures, such as filtration. Proper aseptic procedures are used throughout the Examples. DMEM and F-12 are combined and the individual components are then added to complete the medium. Stock solutions of all components can be stored at −20° C., with the exception of the nutrient source that can be stored at 4° C.
[0076] A vessel suitable for animal cell or tissue culture, e.g., a culture dish, flask, or roller bottle, is used to culture the endocrine progenitor cells. Materials such as glass, stainless steel, polymers, silicon substrates, including fused silica or polysilicon, and other biologically compatible materials may be used as cell growth surfaces. The cells of the invention may be grown on a solid surface or a porous surface, such as a porous membrane, that would allow bilateral contact of the medium to the cultured cells. In addition, the cell growth surface material may be chemically treated or modified, electrostatically charged, or coated with biological agents such as with peptides or matrix components. The preferred growth surface for carrying out the invention is a conventional tissue culture surface coated with Type I collagen.
[0077] The cultures are preferably maintained between about 34° C. to about 38° C., more preferably 37° C., with an atmosphere between about 5-10% CO 2 and a relative humidity between about 80 to 90%. An incubator is used to sustain environmental conditions of controlled temperature, humidity, and gas mixture for the culture of cells.
[0078] Medium used during the first step in progenitor cell activation from a resident progenitor cell can be harvested and used to promote activation of progenitor cells still residing in the expanded culture. Similarly, conditioned medium from proliferating later passage cells can be used to support proliferation of progenitor cells plated at low density. The conditioned medium can comprise from 10-50% of the nutrient medium. Alternatively, a more specialized conditioned supplement is created by removing the common heparin-binding growth factors, concentrating, and desalting the harvested medium. The concentrated supplement can be used at a concentration equivalent to the original starting material. More detailed examples are provided in Example 7 below.
Example 4
[0079] Transplantation
[0080] The invention provides for methods of transplantation into a mammal. A progenitor cell as described above can be transplanted or introduced into a mammal or a patient. In one example, transplantation involves transferring a progenitor cell into a mammal or a patient by injection of a cell suspension into the mammal or patient, surgical implantation of a cell mass into a tissue or organ of the mammal or patient, or perfusion of a tissue or organ with a cell suspension. The route of transferring the progenitor cell or transplantation will be determined by the need for the cell to reside in a particular tissue or organ and by the ability of the cell to find and be retained by the desired target tissue or organ. In the case in which a transplanted cell is to reside in a particular location, it can be surgically placed into a tissue or organ, e.g., the duodenum, or injected into the bloodstream or related organ if the cell has the capability to migrate to the desired target organ as is the case with liver cells which can locate to the liver when injected into the portal circulation or spleen.
[0081] The invention specifically contemplates transplanting into patients isogeneic, allogeneic, or xenogeneic progenitor cells, or any combination thereof.
Example 5
[0082] Treating Insulin-Dependent Diabetes Using Pancreatic Progenitor Cells
[0083] Progenitor cells are useful to replace lost beta cells from Type 1 diabetes patients or to increase the overall numbers of beta cells in Type 2 insulin-dependent diabetic patients. Cadaveric tissue preferably serves as the donor tissue used to produce progenitor cells. Islets are isolated from the tissue and progenitor cells are selected as described herein. The progenitor cells can be transplanted into the patient directly following culture expansion or after a period of differentiation which may be induced by growth factors, hormones and calcium. In one embodiment, the progenitor cells are immunologically tolerated, such that in allogenic transplants, they do not illicit a humoral or immune cell response. In one aspect of this embodiment of the invention, these cells do not normally express MHC class II antigens and do not elicit a costimulatory response that initiates T cell activation.
[0084] In another embodiment of the invention, the recipient of the transplant may demonstrate an immune response to the transplanted cells which can be combated by the administration of blocking antibodies to, for example, an autoantigen such as GAD65, by the administration of one or more immunosuppressive drugs described herein, or by any method known in the art to prevent or ameliorate alloimmune and/or autoimmune rejection.
Example 6
[0085] Drug Discovery
[0086] The unique properties of a population of adult organ progenitor cells, especially a concentrated or substantially pure population, make those cells a highly suitable and desirable tool for characterizing organ regulation and mechanisms of autocrine growth regulation, for example. This is particularly relevant to carcinogenesis and study of how to stimulate in vivo regeneration. The fact that human cells can be used is particularly beneficial. The ability to use the system under chemically defined conditions is also advantageous for research and analysis.
[0087] In some embodiments, the cell population cultured according to the invention is characterized using gene chip analysis, polymerase chain reaction, and/or proteomics analysis at various stages in the method described hereinabove: primary activation from the mature organ, secondary growth and serial passages, and under tertiary conditions promoting differentiation. By comparing the genes activated and proteins produced, and their level of expression at each stage using the same cell strain, differences can be observed that directly relate to changes in regulation of the cell population. These responses can then be compared in more than one human cell strain derived from like or different organs under varying conditions to arrive at common cellular pathways governing human cell populations in the adult organ. These pathways then become candidate targets for biopharmaceutical or pharmaceutical manipulation. Once targets are identified, compounds may be tested in the system to confirm their role in the regulation of the human cells or organotypic tissues.
Example 7
[0088] Establishment and Use of a Progenitor Cell Population from Isolated Human Islets of Langerhans
[0089] Isolation of human islets is performed using the semi-automated method originally proposed by Ricordi (Diabetes 37:413-420, 1988). Procured organs are distended by intraductal infusion of Liberase HI (Roche Molecular Biosciences, Indianapolis, Ind.) or Serva collagenase (Crescent Chemical, Brooklyn, N.Y.). After a process of continuous digestion for approximately 12 to 30 min, tissue is collected into about 8 liters of Hanks solution and washed. Free islets are separated from the other tissue using a continuous gradient of EuroFicoll in a Cobe 2991 cell separator (Cell Tiss Res. 310:51-58, 2002).
[0090] About 200 islet equivalents are plated into 60-mm collagen-coated culture dishes containing 4 ml of primary medium consisting of the 3:1 base of DMEM (no glucose, no calcium, with 4 mM L-glutamine) and Ham's F12 supplemented with the following components with the final concentration of each component indicated: 6 mM L-glutamine (or equivalent), 1×10 −4 M ethanolamine, 1×10 −4 M o-phosphoryl-ethanolamine, 5 μg/ml insulin, 5 μg/ml transferrin, 20 pM triiodothyronine, 6.78 ng/ml selenium, 24.4 μg/ml adenine, 1 mM strontium chloride, 1 mM sodium pyruvate, 100 μM non-essential amino acids, 25 μg/ml aprotinin, 9 ng/ml forskolin and 5 mM glucose.
[0091] Cultures are incubated for 14 days during which time cells spread from the isolated islets. The progenitor small cell population that emerged is harvested by trypsinization at 70% confluence.
[0092] Serial Passage of Islet-Derived Progenitor Cells.
[0093] Proliferating progenitor cells are serially passaged at 4000 cells per cm 2 on Type I collagen coated dishes in a secondary medium consisting of 3:1 DMEM (no glucose, no calcium, with 4 mM L-glutamine): F12 base medium supplemented with the following components with the final concentration of each component indicated: 6 mM L-glutamine (or equivalent), 1 ng/ml epidermal growth factor, 1×10 −4 M ethanolamine, 1×10 −4 M o-phosphoryl-ethanolamine, 5 μg/ml insulin, 5 μg/ml transferrin, 20 μM triiodothyronine, 6.78 ng/ml selenium, 24.4 μg/ml adenine, 1 mM strontium chloride, 1 mM sodium pyruvate, 100 μM non-essential amino acids, and 5 mM glucose. Epidermal growth factor is added at feeding when the cells have established and reached at least 30% confluence. Cells are passaged at 80% confluence or less.
[0094] Heparin Fractionated Conditioned Medium for Selective Stimulation of Progenitor Cells.
[0095] Conditioned medium is harvested from activated proliferating progenitor cell cultures and passed over a preparative heparin-sepharose to remove heparin binding growth factors. The void fraction is concentrated by filtration and desalted using a G-100 sepharose column. The concentrated fraction is filter sterilized, aliquoted and stored at −70° C. until use. The concentrated fraction is reconstituted to its original volume with fresh supplemented base medium and used to support the propagation of late passage or low density progenitor cells.
[0096] Conditioned Medium for the Activation of Progenitor Cells
[0097] Cultures are established from islets as described above. Conditioned medium is harvested from cultures at the intermediate stage during apoptosis of differentiated cells and the beginning of progenitor colony formation. The conditioned medium is concentrated by filtration and desalted using a G-100 sepharose column. The concentrated fraction is reconstituted to its original volume with fresh supplemented base medium and used to support the activation of new progenitor cells derived using cell sorting or other methods such as culture methods to produce cultures of slow-cycling pancreatic small cells.
[0098] In vivo Differentiation of Islet Progenitor Cells
[0099] Islet progenitor cells are serially cultivated to passage 6. The typsinized cells are suspended in base medium and delivered laproscopically via a large needle into the submucosal space of the duodenum. The progenitor cells cluster and differentiate into insulin-producing islet tissue.
[0100] In vivo Delivery of Partially Differentiated Islet Progenitor Tissue
[0101] Islet progenitor cells are serially cultivated to passage 6 and trypsinized. The cells are plated onto tissue culture plastic in the presence of the supplemented basal medium described above with the addition of 1.8 mM calcium chloride, 10 ng/mL forskolin hydrocortisone at 4 μg/ml and an overlay of Type I collagen. Cystic structures form. The cysts may be harvested and delivered as is or treated to undergo further differentiation by the removal of the forskolin and collagenase treatment to remove the collagen overlay. Alternatively, the cell suspension is inoculated in a zero gravity culture system which promotes the formation of suspended cell clusters in the presence of the supplemented basal medium described above with the addition of 1.8 mM calcium chloride and hydrocortisone at 4 μg/ml. The cysts or partially differentiated clusters are injected laporoscopically using a trochar into the submucosal space of the duodenum or alternatively into the portal vein of the liver.
[0102] The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting on the invention described herein. Scope of the invention is thus indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
[0103] Each of the patent documents and scientific publications disclosed hereinabove is incorporated by reference herein for all purposes.
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A population of progenitor cells and methods for obtaining and culturing the progenitor cells, that are useful in fields including regenerative medicine (tissue regeneration), transplantation, and cancer research.
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BACKGROUND OF THE INVENTION
Field of the Invention
German patent DE 195 10 755 C2 discloses a brake arrangement for a rail-bound tractive unit having a plurality of brake systems. In this known brake arrangement, the braking effect is monitored by detecting the deceleration in the case of braking, and a deceleration signal is generated given too small a braking effect. By means of this deceleration signal, measures are automatically triggered which bring about the largest possible residual braking effect by using all of the brake systems which are present in the rail vehicle. In this context, the gritting system is also activated in order to take into account the possible error situation in which failure of the brake which is detected due to the occurrence of the error signal could be due to very low frictional engagement between the wheel and the rail. This leads to a situation in which the wear of the wheel and the rail is, under certain circumstances, unnecessarily increased through the activated gritting system, and grit is spread, possibly also in the region of sensitive rail switch tongues. Furthermore, a gritting system which has a relatively large volume and is therefore expensive has to be used.
BRIEF SUMMARY OF THE INVENTION
The invention is based on the object of specifying a method for monitoring a brake system of a brake arrangement having a plurality of brake systems of a rail vehicle, which method can be carried out comparatively cost-effectively while minimizing the wear and tear to the wheel and to the rail system.
The means of achieving this object are according to the invention a method for monitoring a brake system of a brake arrangement of a rail vehicle, in which the deceleration of the rail vehicle is detected by obtaining a deceleration measured variable and the frictional engagement between the wheel and the rail is detected by obtaining a frictional engagement measured variable; in the case of a small deceleration measured variable and a normal frictional engagement measured variable an error message signal is generated.
A significant advantage of the method according to the invention is that an error message signal is generated only when the brake system which is to be monitored is actually defective or disrupted, with the result that it is only then that, for example, a gritting system is selectively activated and/or a further brake system switched on. In the method according to the invention the grit is therefore handled more economically, which permits a relatively small gritting system and minimizes the wear and tear on the wheels and the rail system.
According to the invention, a further means of achieving the object specified above is a method for monitoring a brake system having at least one brake actuator of a brake arrangement having a plurality of brake systems of a rail vehicle, in which the deceleration of the rail vehicle is detected by obtaining a deceleration measured variable, and the braking force of the at least one brake actuator is measured; in the case of a small deceleration measured variable and a small braking force an error message signal is generated. The brake actuator is preferably an electric motor.
This embodiment of the method according to the invention is advantageous in particular in that a further brake system is not activated here immediately either but instead firstly it is checked whether there is a large probability of the excessively small deceleration being actually due to damage to the monitored brake system. Moreover, this embodiment also has the advantages specified above.
In the method according to the invention, the deceleration of the rail vehicle can be detected in a variety of ways. In order to achieve the most precise possible detection, a deceleration difference actual value is formed from a measured deceleration actual value and a predefined deceleration setpoint value and is compared with a deceleration difference threshold value by forming a deceleration difference intermediate value; in the case of a deceleration difference intermediate value which is above a tolerance value, an error message pre-signal is generated.
In particular in the case of a brake system of a brake arrangement of a rail vehicle for the high-speed field it is considered advantageous if the deceleration setpoint value is changed as a function of a measured speed actual value of the rail vehicle.
In order not to obtain an error message signal every time the rail vehicle comes to a stationary state at a low velocity, the speed actual value of the rail vehicle is advantageously compared with a speed limiting value; in the case of a speed actual value which is below the speed limiting value, the formation of the error message signal is blocked.
Alternatively, it is advantageously possible to measure a speed actual value of the rail vehicle and compare it with a speed limiting value, and in the case of a speed actual value which is below the speed limiting value, the deceleration difference threshold value can be increased.
The frictional engagement between the wheel and the rail can be detected in different ways with the method according to the invention. It is considered particularly advantageous if, in order to detect the frictional engagement between the wheel and the rail at at least one wheel set of the rail vehicle, a slip actual value is measured and is compared with a predefined slip threshold value; in the case of a slip actual value which is above the slip threshold value, a corresponding deceleration difference threshold value is formed as a frictional engagement measured variable.
In this context, the detection accuracy is advantageously increased if the deceleration difference threshold value is increased in accordance with the determined number of wheel sets with slip actual values which are above the slip threshold value.
It can also be advantageous if, in order to detect the frictional engagement between the wheel and the rail at at least one wheel set of the rail vehicle, a frictional engagement actual value in the wheel/rail contact is determined and is compared with a predefined frictional engagement threshold value, and in the case of a frictional engagement actual value which is below the frictional engagement threshold value, a corresponding deceleration difference threshold value is formed as a frictional engagement measured variable.
It is also advantageous here if the deceleration difference threshold value is increased in accordance with the determined number of wheel sets with frictional engagement actual values which are below the frictional engagement threshold value.
In order to check whether in the case of a brake system with brake actuators the latter possibly do not generate any driving effect at all, with the method according to the invention in the case of a brake system with at least one brake actuator a deceleration measurement signal and a speed measured variable of the rail vehicle are advantageously checked with respect to their signs, and in the case of identical signs an error signal for connecting a further brake system is generated immediately.
With the method according to the invention, in order to detect deceleration measured variables and speed measured variables sensors of differing designs are used. It is particularly advantageous to use an inertia sensor package. This applies particularly to the case in which the signs of the deceleration and speed of the rail vehicle are to be determined.
With the method according to the invention with detection of the braking force of brake actuators it is possible to measure this force in different ways. It therefore appears advantageous if the braking force measurement is carried out by means of a force measurement and/or torque measurement on an axle of the rail vehicle which is assigned to the brake actuator.
However, it may also be advantageous to perform the braking force measurement by means of sensors on a deformation body which is reversibly deformed by the braking.
The braking force measurement can also advantageously be carried out in the case of an electric actuator by measuring currents and voltages.
The further processing of the measured braking force is advantageously carried out in such a way that a force difference actual value is formed from a measured force actual value and a predefined force setpoint value, the force difference actual value is compared with a force difference threshold value by forming a force difference intermediate value, and in the case of a force difference intermediate value which is above a tolerance value, a force defect signal is generated.
In the case of a rail vehicle, in particular in the high-speed field, it can be advantageous if the force setpoint value is changed as a function of a measured speed actual value of the rail vehicle.
It can also be advantageous if the force setpoint value is changed as a function of the rotational speed of a wheel set which is connected to the brake actuator.
The invention is also based on the object of proposing an arrangement for monitoring a brake system of a brake arrangement having a plurality of brake systems of a rail vehicle, with which the brake system can be monitored cost-effectively while minimizing wear and tear to the wheel and rail system.
In order to achieve this object, according to the invention an arrangement is provided for monitoring a brake system of a brake arrangement having a plurality of brake systems of a rail vehicle, having a measuring device for the deceleration of the rail vehicle, a measuring apparatus for the frictional engagement between the wheel and the rail, and an evaluation arrangement which is arranged downstream of the measuring device and the measuring apparatus and outputs an error message signal in the case of a small deceleration of the rail vehicle and a normal frictional engagement between the wheel and the rail.
As a result, accordingly the same advantages can be achieved which have already been specified above with respect to the method according to the invention.
A further solution of the object specified above consists in an arrangement for monitoring a brake system having at least one brake actuator of a brake arrangement having a plurality of brake systems of a rail vehicle, having a measuring device for the deceleration of the rail vehicle, a measuring arrangement for the braking force of the at least one brake actuator, and an evaluation arrangement which is arranged downstream of the measuring device and the measuring arrangement and outputs an error message signal in the case of a small deceleration and a small braking force.
As a result, the same advantages can be achieved as are specified above with respect to the method for monitoring a brake system having at least one brake actuator.
With the arrangement according to the invention the measuring device can be embodied in different ways. The measuring device is particularly advantageously embodied in such a way that it forms a deceleration difference actual value from a measured deceleration actual value and a predefined deceleration setpoint value as a deceleration measured variable, it compares the deceleration difference actual value with a deceleration difference threshold value as a frictional engagement measured variable by forming a deceleration difference intermediate value, and in the case of a deceleration difference intermediate value which is above a tolerance value, it generates an error message pre-signal.
The arrangement according to the invention can also be embodied in different ways with respect to the detection of the speed. It appears advantageous if a detection device, in which the speed actual value of the rail vehicle is compared with a speed limiting value, is arranged upstream of the evaluation arrangement, and which detection device, in the case of a speed actual value which is below the speed limiting value, outputs a blocking signal to the evaluation arrangement, with which blocking signal formation of the error message signal in the evaluation arrangement is blocked.
In order to avoid an error message signal being output every time when the rail vehicle comes to a stationary state, the measuring device advantageously has on the input side an evaluation stage which is connected by its input to the output of an inertia sensor package and is embodied in such a way that it outputs at its output a speed measured variable, which is not influenced by the acceleration due to gravity or the centrifugal acceleration, of the rail vehicle. An inertia sensor package is known, for example, from
http://de.wikipedia.org/wiki/Inertialsensor.
Furthermore, it is advantageous if the evaluation stage is also connected on the output side to the measuring apparatus and with its speed measured variable causes an increase in the deceleration difference threshold value to occur at said measuring apparatus in the case of a speed actual value which is below a speed limiting value.
Alternatively, it is also possible that in the case of a speed which is below a predefined threshold, checking for an excessively low deceleration actual value is not performed at all.
With the arrangement according to the invention, the frictional engagement between the wheel and the rail can be detected in different ways; a plurality of possibilities are known for this. It is advantageous if, with the arrangement according to the invention, in order to detect the frictional engagement between the wheel and the rail at at least one wheel set of the rail vehicle, a slip actual value measuring stage is provided in which the measured slip actual value is compared with a predefined slip threshold value, and which, in the case of a slip actual value which is above the slip threshold value, brings about an increase in the corresponding deceleration difference threshold value.
In this context it is also advantageous if a counter for determining the number of wheel sets with slip actual values which are above the slip threshold value is present, which counter generates a signal for increasing the deceleration difference threshold value in accordance with the determined number of wheel sets with slip actual values which are above the slip threshold value.
It also appears advantageous if, in order to detect the frictional engagement between the wheel and the rail at at least one wheel set of the rail vehicle, a measuring stage for the frictional engagement actual value in the wheel/rail contact is provided, which measuring stage is designed to compare the frictional engagement actual value with a predefined frictional engagement threshold value and to form a corresponding deceleration difference threshold value in the case of a frictional engagement actual value which is below the frictional engagement threshold value.
In this embodiment of the arrangement according to the invention a counting stage is advantageously present which detects the number of wheel sets with frictional engagement actual values which are below the frictional engagement threshold value and outputs a counting signal for increasing the deceleration difference threshold value in accordance with the determined number of wheel sets with frictional engagement actual values which are below the frictional engagement threshold value.
In order to check damage to the brake system directly with the arrangement according to the invention having a brake actuator it is advantageous if at least one force/torque meter is arranged upstream of the measuring arrangement of the arrangement according to the invention and is provided on an axle of the rail vehicle which is assigned to the brake actuator.
It is particularly advantageous if the measuring arrangement and the evaluation arrangement are embodied in such a way that they form a braking force difference actual value from a measured braking force actual value and a predefined braking force setpoint value, they compare the braking force difference actual value with a braking force difference threshold value by forming a braking force difference intermediate value, and in the case of a braking force difference intermediate value which is above a tolerance value, they generate a braking force defect signal (LF).
However, it can also be advantageous for a deformation body which can be reversibly deformed by the braking to be provided with sensors for measuring the braking force.
Alternatively or additionally, in the case of an electric actuator it is advantageously possible to assign a current measuring device and/or voltage measuring device thereto for measuring the braking force.
In addition it is considered as advantageous if a high-speed activation stage is provided which is supplied on the input side with a measured variable which is proportional to the deceleration and with a measured variable which is proportional to the speed of the rail vehicle, and said high-speed activation stage is embodied in such a way that it checks the measured variables with respect to their signs, and in the case of identical signs immediately generates an error signal for connecting a further brake system. Such a high-speed connection stage is advantageous not only in the present context but also can generally be used advantageously in any arrangement for monitoring a brake system in which apart from the deceleration the speed of the rail vehicle is also detected.
For this purpose, an inertia sensor package is advantageously provided with which the magnitude and signs of the deceleration and speed of the rail vehicle are determined.
In order to explain the invention further,
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 illustrates an exemplary embodiment of the arrangement according to the invention for monitoring a brake system,
FIG. 2 illustrates an exemplary embodiment of an evaluation stage according to the exemplary embodiment in FIG. 1 ,
FIG. 3 illustrates a further exemplary embodiment of the arrangement according to the invention for monitoring a brake system having a brake actuator, and
FIG. 4 illustrates an additional exemplary embodiment of the arrangement according to the invention in an embodiment which is simplified compared to the exemplary embodiment according to FIG. 3 ,
each of the figures being illustrated as a block circuit diagram.
DESCRIPTION OF THE INVENTION
The arrangement which is illustrated in FIG. 1 for monitoring a brake system of a brake arrangement of a rail vehicle (not illustrated) contains, as essential components, a measuring device 1 for detecting the deceleration of the rail vehicle, a measuring apparatus 2 for detecting the frictional engagement between the wheel and the rail in the case of the rail vehicle, and an evaluation arrangement 3 which outputs an error message signal BF when there is a small deceleration of the rail vehicle compared to the normal case and a normal frictional engagement between the wheel and the rail.
The measuring device 1 contains an inertia sensor package 1 A which has an acceleration sensor which is not illustrated individually and which is parallel to the vehicle longitudinal axis of the rail vehicle. A deceleration actual value a x is measured with this acceleration sensor of the inertia sensor package 1 A. Connected to the inertia sensor package 1 A or to the acceleration sensor thereof is an absolute value former 4 which forms the absolute value of the measured deceleration actual value and generates a positive deceleration actual value d act at its output. Arranged downstream of the absolute value former 4 is in turn a subtractor 5 which is also supplied with a deceleration setpoint value d setp . A deceleration difference actual value Δd act is then produced at the output of the subtractor 5 and therefore also at the output 6 of the measuring device 1 .
The measuring apparatus 2 contains a rotational speed sensor 7 with which the rotational speeds (ω 1 , ω 2 . . . , ω n are measured, wherein the various axle rotational speeds correspond to the various braked wheel sets of the rail vehicle. The axle rotational speed measured variables which are acquired in this way are fed to an element 8 which determines the number k of wheel sets with a low frictional engagement between the wheel and the rail. This element 8 is also supplied with a measured variable v which corresponds to the velocity of the rail vehicle, which measured variable v is obtained in a manner which will be described in more detail below. In the element 8 , the actual value of the slip between the wheel and the rail is determined for each wheel set at which the brake system is to be active, using the wheel radii actual values, the axle rotational speeds which are obtained and the velocity v. If the respective slip actual value exceeds a predefined slip threshold value, the associated wheel set is considered to be slipping and braking with a low frictional engagement. By summing, the element 8 obtains the number k of wheel sets with a low frictional engagement and feeds this value to a nonlinear element 9 . The nonlinear element 9 determines a positive deceleration difference threshold value Δd setp as a function of the number of slipping wheel sets k using a monotonously rising function. This means that as the number of slipping wheel sets k increases, the deceleration difference threshold value Δd setp increases. As a result, the permitted tolerance for the difference between the setpoint deceleration and actual deceleration accordingly increases. Owing to this frictional-engagement-dependent adaptation of the tolerance it is possible with a high level of probability to assume that an error message signal actually occurs only in the case of damage to the brake system used in the rail vehicle. The deceleration difference threshold value signal Δd setp occurs at an output 10 of the measuring apparatus 2 .
The evaluation arrangement 3 which is arranged downstream of the measuring device 1 and the measuring apparatus 2 has on the input side a further subtractor 11 to which on the one hand the deceleration difference actual value Δd act is fed by the measuring device 1 and the deceleration difference threshold value Δd setp is fed by the measuring apparatus 2 ; a deceleration difference intermediate value Δd zw is then present at the input of the further subtractor 11 . If the output of the further subtractor 11 is larger than zero, the logic signal <0 is set at its output to a high level by a downstream two-point element 12 . A high level of the signal LD indicates an excessively low deceleration of the entire rail vehicle and therefore constitutes a deceleration defect signal LD. If the output of the further subtractor 11 is less than zero, the logic signal remains at a low level.
The deceleration defect signal LD is fed to an AND gate 13 to which further logic signals LV, BRt and DS are fed. So that these four signals give rise to a logic error message intermediate signal LB at the output of the AND gate 13 , further conditions must be met, details of which will be given below.
Firstly a braking request must actually be present since this signals that a braking process is underway. Such a braking request is represented by the low level of the logic signal BR with which a lag element 14 is supplied. The signal BR is delayed by the duration of the necessary braking force design by means of this lag element 14 ; this results in the output signal BRt of the lag element 14 with a high level.
The monitoring of the braking effect of the brake system to be monitored takes place appropriately exclusively above a limiting velocity v limit . For this purpose, the measured variable of the velocity v is firstly acquired from the sensor signals of the inertia sensor package 1 A through suitable evaluation in an evaluation stage 15 A. Depending on the direction in which the vehicle is traveling, the sign of the measured variable of the velocity v can be positive or negative, for which reason the measured variable is fed to a further absolute value former 16 . In this absolute value former 16 , a positive velocity actual value v act is formed, which velocity actual value v act is subtracted from the positive velocity limiting value v limit using an additional subtractor 17 ; the absolute value former 16 and the additional subtractor 17 form, together with the evaluation stage 15 A, a detection device 15 . As soon as the velocity actual value is below the velocity limiting value v limit , the output of the additional subtractor is greater than zero and a further two-point element 18 switches its logic output signal as a blocking signal LV to a high level.
Furthermore, in the illustrated exemplary embodiment it is to be ensured that actuators, which are provided for braking and are not illustrated, of the brake system to be monitored do not generate a driving effect. The downstream evaluation element 19 determines whether the signs of the speed v and of the deceleration a x are different. Only if this is the case does the additional element 19 output the logic signal DS with a high level.
If all the signals LD, LV, BRt and DS are present with a high level at the AND gate 13 simultaneously, the latter generates a signal LB which is fed to an OR element 20 . A signal NB of a further AND element 21 , which is supplied with the logic signal DS by the further element 19 and with the signal BRt by the lag stage 14 , is also present on the input side at this OR element 20 .
With the further AND gate 21 it is checked whether or not the brake system to be monitored generates a driving effect. If this is the case, the signal DS has a high level and in the case of a signal BRt also having a high level the logic signal NB at the output of the further AND gate 21 is set to a high level.
The two logic signals LB and NB therefore each signal damage to the monitored brake system with the result that a logic signal BF is output as an error message signal by the OR gate 20 . In the case of a high level, at least one other brake system than that already used is activated by the error message signal BF.
The evaluation stage 15 A which is illustrated in FIG. 2 is, on the one hand, connected on the input side to the inertia sensor package 1 A according to FIG. 1 and also supplied with a stationary state signal ST, which is set to a high level, if the rail vehicle is stationary. On the input side, the evaluation stage 15 A is provided with two splitters 30 and 31 with which the six signals a x , a y , a z and ω x , ω y and ω z are firstly divided into three acceleration signals a x , a y and a z as well as into three rotational speed signals ω x , ω y and ω z . The measuring axis of the sensor which is associated with the acceleration signal a x is parallel to the longitudinal axis of the rail vehicle here. The sensor signals each have bias errors, cross-sensitivity errors, a temperature response, measuring noise etc. In a compensation element 32 , these errors are compensated in the case of the acceleration signals according to known methods. The same occurs with the rotational speed signals in the additional compensation element 33 . Arranged downstream of the two compensation elements 32 and 33 is a transformation element 34 in which, according to the known method, the vector for the acceleration due to gravity of the inertia system is transformed into the sensor coordinate system by, for example, calculating the Euler angle.
The transformed vector serves to compensate the portion of the acceleration due to gravity which is contained in the measured acceleration signals by using a summing element 35 , which is also connected to the one compensation element 32 .
On the input side an element 36 for determining the centrifugal acceleration is also connected to the output of the additional compensation element 33 , in which element 36 the portion of the centrifugal acceleration which is contained in the acceleration signals is obtained according to the known method. A further summing element 37 is arranged downstream of this element 36 for obtaining the centrifugal acceleration and is also connected by a further input to the output of the summing element 35 . The acceleration signals which are compensated by the acceleration due to gravity and the centrifugal acceleration are therefore present at the output of the further subtractor 37 .
A switch 38 which is arranged downstream of the further summing element feeds the compensated acceleration signals to an integrator 39 , downstream of which an additional splitter 40 is arranged. The first signal which is selected by this splitter 40 is the velocity v.
The logic stationary state signal ST is set to a high level by a device which is not shown if the rail vehicle is stationary. As soon as this signaling takes place, the compensated accelerations are set to zero using the element 41 by the switch 38 . Likewise, the time integrals are set to zero by means of a reset input RS of the integrator 39 , as a result of which the drifting time integrals or the velocity are calibrated.
In the transformation element 34 , an integrator can be contained which is used to calculate the transformed vector for the acceleration due to gravity. The integrator is set to new initial values at the high level of the logic stationary state signal ST, which new initial values can depend on the current values of the measured acceleration signals a x , a y and a z .
The exemplary embodiment according to FIG. 3 coincides in large part to that according to FIG. 1 , for which reason identical reference symbols are used for corresponding parts. A measuring apparatus is no longer provided here, instead a deceleration difference threshold value signal Δd setp is permanently predefined. However, a measuring arrangement 49 is arranged downstream of a force sensor 50 which is connected in a way not illustrated to a brake system which is to be monitored and has at least one brake actuator.
In the present exemplary embodiment, by using the sensor 50 the force f is measured in order to obtain the braking effect of the brake actuator (not shown) on an axle of the rail vehicle which is assigned thereto. Since the measured variable which corresponds to the force f is signed, it is initially fed to an absolute value former 51 which forms the positive force actual value f act . The positive force actual value f act is subtracted from the pre definable positive force setpoint value f setp using a subtractor 52 . The force setpoint value f setp can also be here, for example, the absolute value of the setpoint value for controlling the brake actuator, which can preferably be embodied as an electric motor. If the force actual value is below the force setpoint value, the force difference actual value Δf act is greater than zero. The positive force difference threshold value Δf setp is subtracted from the force difference actual value Δf act using a further subtractor 53 . The force difference threshold value Δf setp indicates the permitted tolerance of the difference between the setpoint force and the actual force. If the difference exceeds the tolerance, i.e. if the signal at the output of the subtractor 53 is greater than zero, a two-point element 54 sets the logic signal LF to a high level. If the tolerance is not exceeded, the logic signal LF remains at a low level. A high level of the logic signal LF therefore indicates an excessively low effect of the brake actuator or electric motor, which effect is due to damage to the brake actuator. By means of the AND element 55 , which has here a total of five inputs in contrast to the AND element 13 according to FIG. 1 , the error message signal BF is then generated at the output of an evaluation arrangement 56 which is changed only to a relatively small degree compared to the exemplary embodiment according to FIG. 1 .
In the illustrated exemplary embodiment it is assumed that, owing to the installation direction of the brake actuator or electric motor, the signs of the velocity v and of the force f are always different when the brake actuator or electric motor generates a braking effect. Both signs are compared with one another using the evaluation element 19 . Only in the case of different signs does the logic signal DS at the output of the two-point element 19 receive a high level. The logic signal DS in the exemplary embodiment shown in FIG. 3 thus signals a braking brake actuator or electric motor, while in the exemplary embodiment shown in FIG. 1 it stands for non-driving actuators. The signal DS is further processed in the same way in both exemplary embodiments.
In the exemplary embodiment according to FIG. 4 , in which parts corresponding to parts according to FIG. 3 are provided with the same reference symbols, the arrangement according to the invention is still further simplified compared to the exemplary embodiment according to FIG. 3 . The exemplary embodiment according to FIG. 4 does not in fact require the components 4 and 5 of the measuring device 1 according to FIG. 3 , with the result that here the measuring device is only composed of the inertia sensor package 1 A. The evaluation arrangement 57 does not need the elements 11 and 12 of the evaluation arrangement 56 according to FIG. 3 . The logic signal LD accordingly does not occur. The criterion for an excessively low overall deceleration of the rail vehicle, which could be due to damage to the brake system used, is therefore dispensed with in this exemplary embodiment. Correspondingly, an AND gate 58 with four inputs is sufficient.
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A method and an arrangement monitor a brake system of a brake arrangement of a rail vehicle. To carry out such a method comparatively cost-effectively and gently on the wheels and rails, the deceleration of the rail vehicle is detected with a deceleration measured variable being obtained and the frictional connection between the wheel and rail is detected with a frictional connection measured variable being obtained. In the event of a small deceleration measured variable and a normal frictional connection measured variable, an error message signal is generated. In a brake system with at least one brake actuator, the deceleration of the rail vehicle is detected with a deceleration measured variable being obtained and the brake force of the at least one brake actuator is measured. In the case of a small deceleration measured variable and a low brake force, an error message signal is generated.
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FIELD OF INVENTION
This invention relates to the oxidation with alkaline metal chlorites, and especially sodium chlorite, of dyed textiles which have been dyed with dyes, such as vat dyes or sulfur dyes, in their reduced forms.
BACKGROUND OF THE INVENTION
Of the compounds now recommended to perform such oxidation there can be mentioned alkaline peroxides, hydrogen peroxide and alkaline bichromates. Use of alkaline peroxides or hydrogen peroxide, however, often cause certain overoxidation phenomena to occur particularly in certain dyes belonging to the class of sulfur dyes. Use of bichromates often leads to a notable fading of the shades; further, it involves a pollution of the effluent because of the presence of chrominum salts in the waste waters.
Therefore, it has been proposed to use, as oxidation agents, alkaline metals chlorites and especially sodium chlorite whose use does not give rise to any phenomenon of overoxidation or dulling of the shades. However, it is known that the use of sodium chlorite as an oxidation agent requires the use of this compound at a relatively alkaline pH range; actually, it is imperative in this application to avoid any decomposition of the chlorite solution, which decomposition can occur very rapidly when working in an acid pH zone, at the usual application temperatures, generally close to or greater than 50° C. The chlorine or chlorine compounds that result from the decomposition of alkaline chlorites run the risk of deeply modifying the shades of the dyes applied, and particularly of sulfur dyes.
It is known, on the other hand, that respecting the alkaline conditions inevitably leads to a reduction of the effectiveness of the oxidizing treatment because of the relatively much smaller oxidizing power of the chlorite in an alkaline medium. It is necessary then to perform the oxidation treatments at high temperatures, often greater than 80° C., also at the same time maintaining oxidation periods which are necessarily too long.
SUMMARY OF THE INVENTION
It has now been discovered that it is possible to perform the desired oxidation at the preferred acid pH range between 3.5 and 6.5 and preferably between 4.5 and 6 and at temperatures between 0° and 90° C. and preferably between 30° and 65° C., in an acid medium, without releasing chlorine or chlorine derivatives, if certain chelating agents are added to the oxidation bath. Use of chlorite in the acid medium, for oxidation of dyeings in vat dyes or sulfur dyes, is therefore made possible without causing the slightest alteration of the dyeing characteristics of the oxidized dyes.
This invention therefore has for an object a process of dyeing made by application, in reduced form, of dye materials such as vat dyes or sulfur dyes with alkaline metal chlorites and particularly sodium chlorite in an acid medium, according to which chelating agents are added to the chlorite bath.
DETAILED DESCRIPTION OF EMBODIMENTS
According to a characteristic of the invention, these chelating agents are selected from aminopolycarboxyl acid derivatives. Of the aminopolycarboxyl acids particularly suited for practicing the invention, there can be mentioned alkali metals, alkaline earth metals or amines of ethylenediaminotetraacetic acid, diethylene triaminopentaacetic acid, nitrilotriacetic acid, N-hydroxyethylenediamino-triacetic acid and diaminopropanol tetraacetic acid.
According to another characteristic of the invention, the chelating agents are selected from the derivatives of hydroxy-alkane-phosphonic acids. The derivatives of hydroxy-alkane-phosphonic acids are advantageously compounds derived from C1 to C4 hydrocarbons, such as the salts of hydroxyethane-1, 1-diphosphonic acid or the salts of 1-hydroxy-1, 1, 3-triphosphonic acid.
Besides the fact of preventing any alteration of the dyeing characteristics, the process according to the invention makes possible a considerable improvement of the oxidation rate and a clear reduction of the treatment temperature.
It has been further found that the chelating agents mentioned above exhibit a good stability in relatively concentrated solutions of sodium chlorite. Thus it is possible to achieve concentrated formulations of sodium chlorite and chelating agent, making possible the simultaneous introduction to these two compounds in the oxidation bath and guaranteeing a precise portioning of each of the compounds.
The amount of the above derivatives that should be introduced into the oxidation baths can vary in large proportions depending on the conditions adopted. In a general way, however, this amount will preferably be between 50 and 200% by weight in relation to the amount of chlorite introduced into the baths.
The examples of application, given below by way of indicative and non-limiting illustration, will make it possible to define the possibilities of the invention more concretely. In these examples, all the concentrations are expressed in percentage in relation to the weight of the fabric.
EXAMPLE 1
A previously desized and bleached cotton fabric was dyed with a sulfur dye, applied by the dyeing process described below:
3% of a blue dye referenced in the Color Index as Sulphur Blue 7
3% sodium carbonate
5% sodium sulfide
10% sodium chloride.
After dyeing was performed for 90 minutes at a temperature of 98° C., the sample was quickly rinsed in cold water then treated for 5 minutes in an aqueous oxidation bath having the following composition:
1% of an 80% sodium chlorite solution
0.5% of the tetrasodium salt of ethylene diaminotetraacetic acid (EDTA)
The temperature of the oxidation bath was maintained at 60° C. and the pH adjusted to 5 by addition of acetic acid.
After treatment, a perfectly uniform coloring was obtained the tinctorial characteristics of which corresponded perfectly to the standards of the dye used.
Performed under the same conditions, but in the absence of the EDTA salt in the oxidizing bath, the sample obtained showed a very considerable alteration of the shade, reflecting a practically total deterioration of the coloring initially achieved.
EXAMPLE 2
The dyeing process carried out was identical with that of example 1 but the blue dye was replaced by a brown dye referenced in the Color Index as Sulphur Brown 15. After dyeing, the samples were oxidized for 5 minutes at a temperature of 60° C. with the following baths, the pH being adjusted to 5 by the addition of acetic acid:
(a) 1% of 80% sodium chlorite;
(b) 1% of 80% sodium chlorite to which was added 0.2% of the trisodium salt of nitrilotriacetic acid;
(c) 1% of 80% sodium chlorite to which was added 0.7% of the trisodium salt of nitrilotriacetic acid.
After treatment, the following results were observed:
bath a: very considerable destruction of the dyeing material.
bath b: partial but very clearly perceptible alteration of the coloring achieved.
bath c: coloring perfectly conformed to the standards of the dye used.
EXAMPLE 3
In this example, the operation was performed on cotton samples previously dyed with a vat dye, referenced in the Color Index under the name Vat Brown 53 and used at 2% by the exhaust dyeing process in a reduced vat. After dyeing, the samples were oxidized for 5 minutes at a temperature of 60° C. with the following baths, the pH of the baths having been adjusted to 5 by addition of acetic acid:
(a) 1% of 80% sodium chlorite
(b) 1% of 80% sodium chlorite to which was added 0.5% of the pentasodium salt of diethylenetriaminopentaacetic acid.
After treatment, the results showed a notable degradation of the shade of the sample oxidized in bath (a) but as in the previous examples the sample coming from bath (b) perfectly conformed to the standards of the dye.
EXAMPLE 4
The process carried out was identical with example 1. Oxidation of the dyeing in this case was performed by operating under the following conditions:
Bath (a) 1% of 80% sodium chlorite to which was added 0.5% of tetrasodium salt of ethylenediaminotetraacetic acid;
pH 5.5 by addition of acetic acid;
temperature: 50° C.
Bath (b) 1% of 80% sodium chlorite;
pH 9.5 by addition of sodium carbonate;
temperature: 50° C.
After treatment, identical colorings were obtained corresponding perfectly to the standards of the dye. However, during the treatment it was observed that oxidation of the sample in bath a, namely in acid medium, was obtained after about 15 seconds; the same observation made on bath b showed that oxidation in this case required more than two minutes to be complete.
EXAMPLE 5
The operation was as in example 1, the oxidation being performed under the same conditions with:
1% of 80% sodium chlorite to which was added 0.8% sodium salt of hydroxyethane 1,1 disphosphonic acid.
After treatment, a perfectly uniform coloring was obtained whose tinctorial characteristics corresponded completely to the standards of the dye used.
It will be obvious 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 described in the specification. For example, it will be understood that the textile can be treated in any form, e.g. yarn, woven, knitted, etc. Also, more than one chelating agent may be used in a single bath if desired, and other agents may be present in the oxidizing bath.
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Oxidation of dyeings with reduced vat and sulfur dyes, is accomplished in an improved manner with sodium chlorite under acid conditions of preferably pH 4.5-6 at 30°-65° C. in the presence of chelating agents which prevent the release of chlorine or chlorine compounds, such chelating agents being selected from derivatives of amino carboxylic acids, such as EDTA, and hydroxyalkane phosphonic acids.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims under 35 U.S.C. §119 a the benefit of Korean Patent Application No. 10-2015-0135233 filed on Sep. 24, 2015, the entire contents of which are incorporated herein by reference.
[0002] BACKGROUND
[0003] (a) Technical Field
[0004] The present disclosure relates to a canister apparatus for a vehicle, and more particularly, to a canister apparatus for a vehicle, which reduces noise of a canister by utilizing an air gap configured in the canister.
[0005] (b) Background Art
[0006] In general, a canister is a device used to discharge air contained in vaporized fuel gas generated in a fuel tank into the atmosphere, and is configured to collect and supply a fuel component to an engine. The canister is typically mounted within a vehicle to prevent a loss of fuel vaporized in the fuel tank and prevent the vaporized fuel gas from being discharged into the atmosphere by supplying a fuel component, which is collected when the engine is normally operated (e.g., operated without failure), to the engine.
[0007] The attached FIG. 1 is a view illustrating an operation of a typical canister according to the related art. Referring to FIG. 1 , a canister 3 for collecting vaporized fuel gas is installed between a fuel tank 1 and an engine 2 , and a purge control solenoid valve (PCSV) 4 , which is connected with the canister 3 , is installed to adjust vaporized fuel gas collected by the canister 3 . The purge control solenoid valve (PCSV) supplies the vaporized fuel gas collected by the canister to the engine by receiving a signal from an electronic control unit (ECU).
[0008] In other words, by the PCSV, the vaporized fuel gas collected by the canister is not supplied to the engine before the engine warms up or when the engine idles, but during a normal operation in which the engine completes warming-up and a predetermined load is applied, the vaporized fuel gas is supplied to the engine, and then combusted in the engine. The canister includes active carbon with high adsorptive force to collect vaporized fuel gas therein, and the canister collects vaporized fuel gas generated in the fuel tank, and separates the vaporized fuel gas into a fuel component and air. The air is discharged into the atmosphere, and the fuel component is supplied into an intake pipe by negative pressure in the intake pipe of the engine when the PCSV is opened.
[0009] However, pulsation noise, which occurs when the PCSV is operated, is transmitted through a fuel line and amplified in the canister, and as a result, vehicle NVH characteristics deteriorate. Accordingly, to solve the deterioration in the NVH characteristics, a pulsation chamber, which operates as a damper, is added to the fuel line connected to the canister. However, when performance of the PCSV is changed, pulsation noise increases, and thus, the deterioration in the NVH characteristics may not be solved by the single pulsation chamber.
[0010] Therefore, an installation of an additional pulsation chamber is further required later to cope with the change in performance of the PCSV, and as a result, a size and cost are inevitably increased.
[0011] The above information disclosed in this section is merely for enhancement of understanding the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.
SUMMARY
[0012] The present invention provides a canister apparatus for a vehicle, capable of reducing noise of a canister and reducing bleed emission, which causes environmental pollution, by utilizing an air gap configured in the canister.
[0013] In one aspect, the present invention provides a canister apparatus for a vehicle, in which a first partition wall and a second partition wall may be installed at a predetermined interval in a flow direction of gas in an air gap space disposed in a canister body. The first and second partition walls may be disposed at predetermined positions in the air gap space, and a section of frequency, where noise is filtered, may be determined based on the positions of the first partition wall and the second partition wall.
[0014] In addition, a gas may flow from one end to the other end of the air gap space. The first partition wall and the second partition wall may be installed to form a predetermined angle with respect to a flow direction of gas flowing into the air gap space, and specifically, the first partition wall and the second partition wall may be installed to form a right angle with respect to a movement direction of gas flowing into the air gap space. Further, a vent aperture and a vent pipe for a gas flow may be formed on at least one of the first partition wall and the second partition wall. A gas diffusing aperture for diffusing gas passing through the vent pipe may be formed in the vent pipe, and, the vent pipes formed on the first partition wall and the second partition wall may be formed opposing each other (e.g., facing away from each other).
[0015] According to the canister apparatus for a vehicle according to the present invention, the partition walls, disposed at predetermined positions in the air gap space in the canister, may be installed, thereby improving the vehicle NVH characteristics, and reducing the discharge amount of bleed emission that causes environmental pollution. Therefore, it may be possible to eliminate the existing pulsation chamber configured in the fuel line connected to the canister, reduce costs accordingly, and expect an effect of increasing a size of the pulsation chamber by utilizing a space several times greater than the existing pulsation chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above and other features of the present invention will now be described in detail with reference to exemplary embodiments thereof illustrated in the accompanying drawings which are given hereinbelow by way of illustration only, and thus are not limitative of the present invention, and wherein:
[0017] FIG. 1 is a view illustrating an operation of a typical canister according to the related art;
[0018] FIGS. 2 and 3 are views illustrating a canister according to an exemplary embodiment of the present invention;
[0019] FIGS. 4 and 5 are a longitudinal cross-sectional view and a transverse cross-sectional view of the canister according to the exemplary embodiment of the present invention; and
[0020] FIG. 6 is a view illustrating a noise reduction principle for the canister according to the present invention.
[0021] Reference numerals set forth in the Drawings include reference to the following elements as further discussed below:
[0022] 100 : canister body
[0023] 110 : first active carbon filling space
[0024] 120 : second active carbon filling space
[0025] 130 : auxiliary canister
[0026] 140 : air gap space
[0027] 150 : first partition wall
[0028] 152 : vent aperture
[0029] 154 : vent pipe
[0030] 155 : gas diffusing aperture
[0031] 160 : second partition wall
[0032] 162 : vent aperture
[0033] 164 : vent pipe
[0034] 165 : gas diffusing aperture
[0035] It should be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the invention. The specific design features of the present invention as disclosed herein, including, for example, specific dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment. In the figures, reference numbers refer to the same or equivalent parts of the present invention throughout the several figures of the drawing.
DETAILED DESCRIPTION
[0036] It is understood that the term “vehicle” or “vehicular” or other similar term as used herein is inclusive of motor vehicles in general such as passenger automobiles including sports utility vehicles (SUV), buses, trucks, various commercial vehicles, watercraft including a variety of boats and ships, aircraft, and the like, and includes hybrid vehicles, electric vehicles, combustion, plug-in hybrid electric vehicles, hydrogen-powered vehicles and other alternative fuel vehicles (e.g. fuels derived from resources other than petroleum).
[0037] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0038] Unless specifically stated or obvious from context, as used herein, the term “about” is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. “About” can be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 32%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from the context, all numerical values provided herein are modified by the term “about.”
[0039] Hereinafter, reference will now be made in detail to various exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings and described below. While the invention will be described in conjunction with exemplary embodiments, it will be understood that the present description is not intended to limit the invention to those exemplary embodiments. On the contrary, the invention is intended to cover not only the exemplary embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the invention as defined by the appended claims.
[0040] Hereinafter, an exemplary embodiment of the present invention will be described in detail with reference to the accompanying drawings.
[0041] A canister according to an exemplary embodiment of the present invention operates to collect vaporized fuel gas in a fuel tank, discharge air into the atmosphere, and supply a fuel component to an engine. Referring to FIGS. 2 and 3 , at one side (e.g., a first side) of a canister body 100 having an internal space, a vaporized gas inlet portion 102 into which vaporized fuel gas flows, a fuel discharge and supply portion 104 from which the fuel component collected from the vaporized fuel gas is discharged, and an air discharge portion 106 from which air separated from the vaporized fuel gas is discharged may be formed.
[0042] The vaporized gas inlet portion 102 may be connected to the aforementioned fuel tank, the fuel discharge and supply portion 104 may be connected to the engine through the above-described purge control solenoid valve (PCSV), and the air discharge portion 106 may be configured to discharge air into the atmosphere. The inside of the canister body 100 maybe filled with active carbon to more easily collect the fuel component, and accordingly, the space, filled with active carbon, may be separated into a first active carbon filling space 110 and a second active carbon filling space 120 . The first active carbon filling space 110 may be connected with the vaporized gas inlet portion 102 to allow gas to flow therebetween, and the second active carbon filling space 120 may be connected with the first active carbon filling space 110 through an air gap space 140 to allow gas to flow therebetween.
[0043] Referring to FIG. 4 , the air gap space 140 may be a vacant space that is not filled with the active carbon, and may be formed to be adjacent to an auxiliary canister 130 installed in the second active carbon filling space 120 , and disposed at a position surrounded by the first active carbon filling space 110 , the second active carbon filling space 120 , and the auxiliary canister 130 . In other words, the air gap space 140 may be a vacant space that is not filled with active carbon in the second active carbon filling space 120 , and a first partition wall 150 and a second partition wall 160 may be installed to apply a gas flow closing shape or an air flow closing shape to an air gap space 140 .
[0044] Referring to FIGS. 4 and 5 , the first partition wall 150 and the second partition wall 160 may be provided in the form of a panel that may separate the air gap space 140 in the gas flow direction, respectively, and as a portion of the canister body 100 , the first partition wall 150 and the second partition wall 160 have shapes that may come into close contact with (e.g., abut) the canister body 100 and the auxiliary canister 130 that surround the second active carbon filling space 120 .
[0045] In particular, the first and second partition walls 150 and 160 may be installed at a predetermined interval in a flow direction of gas flowing into the air gap space 140 , and particularly, the first and second partition walls 150 and 160 may be disposed at predetermined positions in the air gap space 140 , to set a section of wavelength where noise (e.g., pulsation noise) is filtered based on the position of the partition walls. Furthermore, an emission damper space may be formed to reduce an emission amount discharged to the exterior.
[0046] The setting of the section of wavelength, where the noise is filtered based on positions of the partition walls, may be performed by a principle of band stop filter as illustrated in FIG. 6 , and the section of wavelength, where noise (pulsation noise) is filtered, may be determined based on predetermined positions of the partition walls 150 and 160 , and with a principle that the wavelength is related to the frequency, and the section of frequency, where noise will be filtered may be determined For example, noise may be reduced with respect to a frequency section of about 100 Hz to 400 Hz based on the positions of the partition walls, and at the entirety of the frequency section (e.g., about 100 Hz to 400 Hz) determined based on the positions of the partition walls in the air gap space 140 , noise may be reduced. In particular, a frequency section may be determined using the equation v=f×(λ) which is based on the positions of the partition walls (λ). Here, the v is fixed to a constant value as the velocity of sound of the air gap space 140 , that is, the velocity of sound in the air, and the v is a value obtained by adding the length of a vapor line, which corresponds to a distance of fluid movement from the fuel discharge and supply portion 104 to the engine, a distance from the fuel discharge and supply portion 104 to the air gap space 140 inside the canister body 100 , and a distance from the front end of the air gap space 140 to the first partition wall 150 or the second partition wall 160 . Accordingly, the f, which indicates frequency, is determined by the value of λ.
[0047] In addition, the air gap space 140 may be formed as a gas flow occurs (e.g., as the gas flows) from a first end (into which gas flows) to a second end (from which gas is discharged), and referring to FIG. 5 , the first and second partition walls 150 and 160 may be installed to form a predetermined angle with respect to a flow direction of the gas flowing into the air gap space 140 . For example, the first and second partition walls 150 and 160 may be installed to form a right angle (e.g., about 90 degree angle) with respect to a movement direction of the gas flowing into the air gap space 140 .
[0048] When the gas flow closing shape is applied to the air gap space 140 using the first partition wall 150 and the second partition wall 160 , performance in terms of a reduction in noise of the canister may be improved, but venting resistance may increase, and thus, a purge rate of the vaporized fuel gas purged to the engine may be reduced. Since vehicle power performance may be reduced when the purge rate is reduced, an optimal flow path for reducing venting resistance may be set. Therefore, to form a gas flow path for reducing venting resistance, a plurality of vent apertures 152 and 162 for a gas flow may be formed in at least one of the first partition wall 150 and the second partition wall 160 installed in the air gap space 140 .
[0049] The plurality of vent apertures 152 and 162 may be formed by changing a condition such as the size and the interval thereof, and as illustrated in FIGS. 3 and 4 , the plurality of vent apertures 152 and 162 may be formed to be arranged in a row in the transverse direction and the longitudinal direction, and may have about the same size. In addition, vent pipes 154 and 164 through which a substantial amount of gas may flow compared to the vent apertures 152 and 162 may be formed on at least one of the first partition wall 150 and the second partition wall 160 .
[0050] The vent pipes 154 and 164 may be pipes having a predetermined diameter, formed in the form of a pipe that penetrates the partition wall. For example, the venting pipes 154 and 164 may be penetratively attached to or formed integrally with the partition walls to cause an axial direction to form a right angle with the partition walls 150 and 160 . Further, to diffuse gas passing through the vent pipes 154 and 164 , particularly, to more smoothly diffuse gas, which passes through the vent pipes 154 and 164 and then flows into the space between the first partition wall 150 and the second partition wall 160 , adjacent to each other at a predetermined interval, the vent pipes 154 and 164 formed on the respective partition walls 150 and 160 may be formed at positions where the vent pipes 154 and 164 do not face each other in the upward and downward direction and in the left and right direction (e.g., vertically and horizontally) with respect to the partition walls 150 and 160 . In other words, the vent pipes 154 and 164 may be formed to oppose each other.
[0051] For example, as illustrated in FIGS. 3 and 5 , any one vent pipe of the two vent pipes 154 and 164 formed on the first partition wall 150 and the second partition wall 160 may be formed at a left lower side of the partition wall (e.g., a partition wall disposed relatively forward), and the other vent pipe may be formed at a right upper side of the other partition wall (e.g., a partition wall disposed relatively rearward), and thus, the two vent pipes 154 and 164 may be disposed to be misaligned in a diagonal direction. Thus, a first pipe may be formed in at a first position and a second pipe may be formed at a second position that opposes the first position. In addition, to more smoothly diffuse gas, which passes through the vent pipes 154 and 164 and then flows into a space between the first partition wall 150 and the second partition wall 160 , a plurality of gas diffusing apertures 155 and 165 may be formed in an outer circumferential surface of the vent pipes 154 and 164 in a circumferential direction and in an axial direction.
[0052] As described above, the gas flow closing shape, which may reduce an emission damper space and venting resistance for reducing the amount of emission discharged to the exterior by utilizing the air gap space 140 in the canister body 100 , may be applied, to form a structure for bleed emission diffusion prevention and a resonator structure in the canister, thereby improving NVH performance, and to reduce the discharge amount of bleed emission discharged to the exterior. To increase the amount of fuel components collected from the vaporized fuel gas, the aforementioned auxiliary canister 130 may be additionally installed in the canister body 100 , and configured to collect the fuel component from the vaporized fuel gas using a honeycomb structure.
[0053] The invention has been described in detail with reference to exemplary embodiments thereof. However, 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.
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A canister apparatus for a vehicle is provided. The apparatus reduces noise of a canister by utilizing an air gap disposed in the canister, and partition walls, which are disposed at predetermined positions in the air gap space in the canister. As a result, vehicle NVH characteristics are improved and the discharge amount of bleed emission that causes environmental pollution is reduced.
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BACKGROUND
The present invention relates to a power management method, and in particular, to a system and method for performing power management automatically without software protocols.
Regulation of power consumption is an important concern in computer systems, particularly in mobile computers using a battery as a power supply. The Advanced Configuration and Power Interface (ACPI) standard is implemented in computer systems for managing power consumption, the architecture thereof is shown in FIG. 1 a.
ACPI is implemented through cooperation of hardware and software. According to the design, power management is accomplished by delivering commands from the operating system to the hardware through drivers and the system management bus (SMBUS), and power consumption is reduced by decreasing the operating voltage and frequency accordingly. FIG. 1 a shows a conventional system architecture comprising a software layer 101 , a hardware layer 103 and an ACPI layer 112 therebetween. The operating system 104 in software layer 101 comprises an Operating System Power Management (OSPM) API, labeled 106 in the figure. The OSPM 106 is executed to assess utilization of an application 102 , and regulate power consumption accordingly. Thus a corresponding power management command is delivered to the ACPI layer 112 through device drivers 108 and ACPI driver 110 and is transmitted to the hardware layer 103 through SMBUS.
The ACPI layer 112 architecture comprising programs, control tables and ACPI registers resides between the hardware and software layers. In hardware layer 103 , the power management command is received by the South Bridge 124 , and is transferred to voltage controller 122 and frequency controller 126 through System Management Bus (SMBUS) 128 to control voltages and frequencies. Based on the power management command, the voltage controller 122 can adjust operating voltages of Central Processing Unit (CPU) 114 , Accelerated Graphics Port (AGP) 116 and memory 120 , and the frequency controller 126 generates corresponding operating frequencies for each of the system components.
When hardware performance is decreased to reduce power consumption, however, the software driven power management efficiency is compromised and reliability suffers as the software is reliant on hardware for execution. For example, when CPU 114 enters state C 3 , data in CPU 114 is lost, data in the cache loses consistency, and the system is unable to handle master requests and interrupt requests. A considerable number of clock cycles are required to recover from the state C 3 , thus the software power management system is unable to reflect hardware utilization in real-time, thus reducing power consumption efficiency.
SUMMARY
An embodiment of the invention provides a real-time power management method. The method comprises the following steps. First, utilization of a system component is assessed through a first unit, and a sideband signal is generated through a second unit according to the utilization and a code table. Thereafter, system component parameters are adjusted by a set of sideband pins based on the sideband signal and a parameter table, wherein the sideband pins are connected to the second unit, for transmitting the sideband signal directly without requiring software control.
The generating step comprises the following steps. First, a utilization load class is classified by the first unit, and the sideband signal is generated through looking up the load class in the code table by the second unit. The code table comprises a plurality of load classes previously defined based on the system specifications. The parameter table can be a voltage table built through software protocols defining voltage parameters corresponding to each load class, or a frequency table defining frequency parameters corresponding to each load class. The system component can be a central processing unit, memory or accelerated graphics port. The first unit is a North bridge, and the second unit is a South bridge.
Another embodiment of the invention provides a real-time power management system, for use in a computer system. The system comprises a first unit, a second unit, a system management bus, a controller and a plurality of sideband pins. The first unit assesses utilization of a system component to obtain load information, and the second unit generates a sideband signal based on the load information. The system management bus delivers power management commands through software protocols, and the controller receives the sideband signal to adjust parameters of the system component. The sideband pins, connecting the second unit and the controller, delivers the sideband signal directly without utilizing software protocols.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description, given by way of example and not intended to limit the invention solely to the embodiments described herein, will best be understood in conjunction with the accompanying drawings, in which:
FIG. l a is a block diagram of conventional power management interface (ACPI);
FIG. 1 b is a timing chart of conventional power consumption and throttle;
FIG. 2 a is a block diagram of power management interface according to an embodiment of the invention;
FIG. 2 b is a timing chart of power consumption and throttle according to an embodiment of the invention;
FIG. 3 is a code table code table 202 according to an embodiment of the invention;
FIG. 4 is a frequency table frequency table 204 according to an embodiment of the invention; and
FIG. 5 is a voltage table voltage table 206 according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
A detailed description of the present invention is provided in the following.
As the South Bridge is the key component utilized for system frequency and voltage control, power consumption can be reduced by manipulation thereof, thus an automatic frequency and voltage control mechanism can be added as an extension to perform real-time power management. Active power management via the South Bridge can be more precise and faster than passive software control. Additionally, conventional power management conforming to the system management bus (SMBUS) standard takes at least 0.3 millisecond to deliver a command (assuming that clock rate is 100 kilo-hertz, and the command occupies 30 clock cycles). If simultaneous control of voltage and frequency are required, it takes at least 1 millisecond to accomplish the operation. Consequently, an embodiment of the invention provides sideband pins transferring sideband signals for rapid and automatic control of system frequency and voltage.
The block diagram of an embodiment of the invention as shown in FIG. 2 a and FIG. 2 b does not correspond to software, instead, a set of registers, code table 202 is added to South Bridge 224 as an extension, for reference of power management. A plurality of sideband pins are extended from South Bridge 224 , coupled to voltage controller 222 and frequency table 226 , such as GPOa, GPOb and GPOc in FIG. 2 a . The number of sideband pins determining the number of load classifications is not limited to the embodiment.
North Bridge 118 , among system components, handles load information of CPU 114 , AGP 116 , memory 120 and South Bridge 224 , and further comprises information unknown to CPU 114 , making it the most suitable candidate to serve as a system monitor. In this embodiment, utilization information of CPU 114 , memory 120 and AGP 116 are obtained by the North Bridge 118 and sent to the South Bridge 224 . Through North Bridge 118 , the utilization information can be presented as digital values synchronized with corresponding system components in real-time, thus no additional routine functions are required for sampling among numerous data to obtain the utilization information. After the utilization information is transferred from the North Bridge 118 to the South Bridge 224 , it is categorized into classes, such as “HIGH”, “NORMAL”, “LOW”, “LOWEST”. As shown in FIG. 3 , the code table 202 in the South Bridge 224 defines a lookup table indicating which classification corresponds to which signal to output. For example, a combination of GPOa, GPOb and GPOc each having two states, high and low, generates eight variations. The code table 202 is not limited to the described embodiment, and may comprise more detailed lookup tables corresponding to various system components therein. The code table 202 can be generated by the South Bridge 224 automatically according to the system specification when power is on, and can also be manually programmed through an external input. Based on the utilization information from North Bridge 118 and the code table 202 in South Bridge 224 , a corresponding sideband signal is generated by the South Bridge 224 and transferred to voltage controller 222 and frequency controller 226 through the sideband pins GPOa, GPOb and GPOc. The voltage controller 222 is capable of tuning operating voltages of CPU 114 , AGP 116 and North Bridge 118 , and comprises a voltage table 206 , as shown in FIG. 5 . By referencing voltage table 206 , the sideband signals “HIGH”, “HIGH” and “HIGH” from GPOa, GPOb and GPOc can be interpreted as increasing the operating voltage by 10%. The voltage controller 222 then increases the operating voltage supplying a corresponding system component by 10%. Conversely, the frequency controller 226 controlling operating frequency of each system component, references the frequency table 204 in FIG. 4 to reduce the corresponding operating frequency by 20% when receiving sideband signals “LOW”, “LOW”, and “HIGH” from GPOa, GPOb and GPOc, and generates the reduced frequency for the corresponding system component accordingly.
The sideband signals are transferred through sideband pins GPOa, GPOb and GPOc rather than the conventional SMBUS 128 conforming to ACPI standards, thus hardware extension of the South Bridge 224 , voltage controller 222 and frequency table 226 are required to penetrate the speed bottleneck. Similar to the code table 202 , the frequency table 204 and voltage table 206 can either be generated by system firmware automatically according to the system specification when power is on, or be manually programmed through an external input.
In FIG. 2 a , for example, if the ordinary operating voltage of CPU 114 is 3.3 volts and the operating frequency is 2.0 Gigahertz. When the CPU 114 has exceedingly high utilization, the code table 202 , frequency table 204 and voltage table 206 are previously defined to increased voltage by 1% and increased frequency by 10%. The North Bridge 118 first detects that the utilization of CPU 114 is 100%, and the detected utilization information is transferred to South Bridge 224 and looked up in the code table 202 . A class “HIGHEST” is then determined and corresponding sideband signals are delivered from the South Bridge 224 to the voltage controller 222 and frequency table 226 through GPOa, GPOb and GPOc. After looking up the voltage table 206 and the frequency table 204 , the voltage controller 222 applies 3.33 volts to the CPU 114 , and the frequency table 226 applies 2.2 Gigahertz to the CPU 114 . Therefore, in addition to power management, embodiments of the invention also provide additional performance when necessary.
FIG. 1 b is a timing chart of a conventional system utilization and throttle. The utilization curve 301 changes with time, and the throttle curve 302 indicates power adjustment under conventional software control. For comparison, FIG. 2 b provides a timing chart of an embodiment of the invention that throttles faster and more precisely than the conventional power management system, as the throttle curve 303 shows. When needed, “over-clocking” by x % can be applied to provide additional performance, therefore embodiments of the invention not only reduce power consumption but also maximize hardware performance.
In summary, embodiments of the invention provide a South Bridge 124 comprising a plurality of sideband pins to control voltage and frequency of system components. By cooperating with an internal monitoring mechanism provided by North Bridge 118 , and avoiding software inefficiency, the performance of the system is maximized and power consumption is minimized.
While the invention has been described by way of example and in terms of the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. To the contrary, it is intended to cover various modifications and similar arrangements (as would be apparent to those skilled in the art). Therefore, the scope of the appended claims should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements.
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A system and method of real-time power management for use in computer systems. The system utilization is assessed by a North bridge, and a result is transferred to a South bridge. Thereafter, through transmitting sideband signals to a voltage controller and a frequency controller by sideband pins, the North Bridge provides faster and more efficient power management performance than the system management bus (SMBUS).
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BACKGROUND
[0001] The disclosure concerns an apparatus in the form of an applicator to deposit a viscous, flowable mass to a surface, such as roadways, parking areas, air port runways and the like. The disclosure also concerns a traffic printer comprising a number of such applicators and a method of cleaning the valves and their openings.
[0002] \Norwegian patent No. 311733 (Trysil Maskin) teaches an apparatus intended for suspension to a vehicle for which a pressurized viscous mass container is supplied with viscous mass from a storage container. The mass is discharges thorough a member arranged to be opened and closed by a flapper and having a discharge slot facing the surface below, the axis thereof being perpendicular to the direction of movement. The member arranged to be opened and closed is connected to a secondary valve member which is arranged with an axis parallel to the discharge slot in a cylindrical sleeve shaped element. The secondary valve member is provided with a longitudinally extending groove in the periphery which can connect an inlet slot from the mass container with the discharge slot at the flapper.
[0003] This apparatus works satisfactory for traditional application of longitudinal stripes on road surfaces but is not designed for application of patterns and neither for controlled application of marker coatings with improved reflection function for wet marking and for masses which needs heating.
[0004] Norwegian patent No. 316 123 (Trysil Maskin) describes an apparatus for suspension to or integration with a vehicle, comprising a pressurized mass container for a liquid, flowable mass from a storage container, said mass being discharged through a valve member having a row of close adjacently arranged flapper elements that can be activated individually. Even tough this design allows application of simple patterns, it does not allow application of more complicated patterns or symbols.
[0005] Another disadvantage of the prior art equipment is that the flapper openings tends to get clogged and that no satisfactory measures have been found to remedy that.
[0006] From Norwegian patent No. 325 827 is known an apparatus for suspension to or integration with a vehicle for depositing a flowable substance that can form continuous or divided marker coatings on road surfaces, parking areas and the like, comprising a container for the flowable substance, the substance being discharged through a valve member having a number of computer controlled, close adjacently arranged valve elements that can be activated individually by means of a row of activating members having connecting elements to the individual valve elements. This apparatus, however, no more than the other, provides a solution as how to deposit complex patterns, signs or symbols to a surface.
[0007] Advanced signs, symbols and writing on road surfaces must still be applied manually by personnel which for that purpose normally must work on a closed part of a partly open road, with the risk for accidents involved in being so close to traffic. It would have been a very significant advantage both in terms of safety and economy if many of the tasks today being made manually by personnel working very close to motorized traffic could be performed more automatically and by personnel mainly working inside a vehicle. There is thus a need for an apparatus which is able to “write” any desired signs and symbols to a surface such as a roadway.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Below the invention is described in further detail with reference to the accompanying drawings, in which:
[0009] FIG. 1A provides a side sectional view of an embodiment of an applicator according to the present disclosure,
[0010] FIG. 1B provides a top view of the top cover of the applicator from FIG. 1 .
[0011] FIG. 1C shows an enlarged section of a detail shown in FIG. 1A .
[0012] FIG. 2 provides a sectional view of a detail from FIG. 1A .
[0013] FIG. 3 provides a schematic top view of a number of assembled applicators in an assembly ready for use.
[0014] FIG. 4A shows schematically the assembly from FIG. 3 in use.
[0015] FIG. 4B shows schematically the assembly from FIG. 3 when being cleaned according to the disclosed method.
DETAILED DESCRIPTION
[0016] With reference to the drawings wherein like numerals represent like parts throughout the Figures, an applicator, a traffic printer and a method of cleaning valves thereof are disclosed.
[0017] By “viscous mass” as used herein is understood any mass which are flowable at a convenient elevated temperature and which has a viscosity which prevents it from flowing significantly when applied to a surface typically at ambient temperature, such as temperatures in the range from 5° C. to 40° C. Higher or lower temperature may occur exceptionally. Typical masses are resin based but can contain fragments/particles of other materials, e.g. to increase friction or to improve light reflection from a completed, set mass on a surface.
[0018] With “surface” as used herein is understood typically a roadway, a parking space, an airport or other areas having paved surface, such as covered by asphalt or concrete, especially surfaces intended for vehicles.
[0019] While the complete “traffic printer” according to the present disclosure below is described as a unit assembled from a number of applicators having a common source of the viscous mass, exemplified as comprising five applicators arranged in two rows, more or fewer applicators than those described and illustrated are possible. It is furthermore an option to produce applicators having valves so close to those side walls of the applicators which are parallel to the direction of movement, that the need for applicators in more than one row is eliminated. In the same manner with which a printer for a computer comprises a complete product even though it requires connection to a computer and use of appropriate software (drivers) to function, the present traffic printer according to the present invention is an independent product even though it requires connection to a computer and accompanying software to function in an optimal manner.
[0020] FIGS. 1A-C shows an applicator 11 according to the present disclosure, comprising a number of openings 12 in the bottom wall 13 , said openings being arranged to receive and hold tightly, e.g. by a threaded connection in the depicted drawings, valves 14 which can be opened and closed by valve lifters 18 via valve stems 19 . The valve stems 19 extend through openings 20 in the applicator top cover 21 , and are supported in the openings 20 by packer-free bushings 22 typically made of metal but which may also be made of ceramics or other appropriate durable or wear resistant synthetic materials.
[0021] The applicator 11 has in a known manner channels arranged to circulate hot oil to ensure an even and controllable viscosity of the mass to be deposited and to prevent it from setting in the applicator or its openings and valves.
[0022] The valve 14 as such comprises an outer valve sleeve 15 which has at least one through opening 16 forming a flow passage from the outside to the inside of the valve sleeve 15 . The inner surface of the valve sleeve is smooth and precisely adapted to the outer surface of a valve plug 17 which is slidably arranged in the valve sleeve 15 , attached to the valve stem 19 and movable upwards and downwards within limits determined by the valve sleeve, by means of valve plunger 18 attached to the upper end of the valve stem 19 or separably from the latter. The valve sleeve 15 typically has an inner cylinder surface but can also have en inner surface of another shape. In terms of manufacture cylindrical shape is typically the simplest shape and in such a case the valve plug 17 has similar cylindrical piston shape. The valve stem 19 is preferably split in a joint 23 which is adapted to accommodate for tolerance variations with regard to the positioning of the holes 20 in the applicator top cover 21 in relation to the openings 12 in the applicator bottom wall 13 . The valve sleeve 15 is adapted to be sealingly and tightly attached in the lower opening 12 , preferably by threaded connection.
[0023] Each valve stem 19 is attached to a valve lifter 18 which can reciprocate the valve stem 19 up and down respectively by a power impulse which may be hydraulic, pneumatic or in the form of an electromechanically controlled impulse.
[0024] According to a preferred embodiment the applicator has two rows of openings 12 , provided with valves 14 , extending across the width of the applicator. According to a further embodiment the applicator has at least three rows of openings 12 and valves 14 respectively. A person skilled in the art readily understands that the higher the number of rows of valves, the denser the pixels may be arranged so that finer details can be achieved in the printout, provided the valve size is reduced in a manner corresponding to the increase in number.
[0025] It is preferred to have at least five openings 12 and valves 14 respectively in each row, more preferred at least eight and most preferred at least ten.
[0026] FIG. 1B shows the top cover 21 with openings 20 and bushings 22 , the bushings functioning as packer-free sealings around the valve stems 19 . Alternatively the valve stems 19 through the openings 20 in the top cover 21 can be provided with glands.
[0027] FIG. 1C shows an enlarged section of two valves 14 from FIG. 1A , the left of which being in a closed position while the right of which being in an open position, the valve plug ( 17 ) being lifted to an extent an open passage is formed through the opening 16 from the outside of the valve sleeve 15 to its inside. The viscous mass 31 is then allowed to flow through the valve as indicated by arrows on the right drawing indicates.
[0028] To ensure flexibility of the system, the power generating unit transmitting power impulses must be arranged to be controlled by a computer processor which can have any outer shape, for instance being a portable PC.
[0029] FIG. 2 shows an enlarged section of a valve 14 , valve stem 19 and valve lifter 18 from FIGS. 1A-1C . Joints 23 and 23 ′ are shown also, below and above the applicator top cover 21 . The valve stem 19 is not necessarily bendable in said joints, but the joints introduce a certain slack that can compensate for possible tolerance variations in the localization of the holes 12 in the bottom wall 13 compared to the holes 20 in the top cover 21 . The joints 23 and 23 ′ may alternatively be real, bendable joints which may be oriented with a mutual angular orientation of 90 degrees to most adequately compensate for variations in an arbitrary direction.
[0030] FIG. 3 shows an assembly 37 in the form of a carriage 38 having a width corresponding to the widest area in which printing of letters or other symbols is desired. The depicted assembly 37 (i.e., traffic printer) comprises five applicators 11 arranged in a sideways manner and in order to ensure complete overlap, three are arranged in one row while two are arranged behind those three and laterally biased to cover the lateral interstices between the three applicators in front. In use, the viscous mass is charged to the center applicator 11 through charge chute 33 and is passed on to the other applicators through connecting conduits 34 and recycled to a main container 41 ( FIG. 4A ) through recycle hoses 35 . Each individual applicator 11 of the traffic printer 37 is shown having wheels 36 allowing a vertical position of the individual applicator that is independent of the other ones, determined by the local level of the surface below. This ensures that each applicator can be positioned near the surface even when there are local level variations in the direction perpendicular to the direction of movement for the traffic printer.
[0031] FIG. 4A shows schematically a traffic printer 37 in use, suspended behind a vehicle 40 which comprises a main container 41 for the viscous mass. The carriage 38 of the traffic printer 37 is held by arms 42 that can be controlled e.g. hydraulically. Supplying and recycling of viscous mass is made through flexible hoses 43 .
[0032] In the practice use of traffic printer 37 , the controlling of the opening and closing of valves of each applicator is performed a computer program to which the user inputs information of the signs or symbols to be printed. “Printing” on a road or like surface by the traffic printer via moving vehicle is mimicked on a smaller scale by printing on a piece of paper moving past a printer head. In the same manner that the printing software controls flow of ink to printer nozzles over the paper, with dependence on the speed with which the paper moves past the printer head the speed at which the valves are opened and closed must be controlled in dependence on the velocity with which the vehicle with the traffic printer according to the present invention moves. It is not certain that the velocity will be constant in the “printout period” and the computer system therefore uses real time information of the actual speed or other movement or positioning. The mechanism for systems for controlling speed, movement and positioning is not described in further detail.
[0033] A particular feature that the controlling software must account for, in a case as shown in FIG. 3 , is the fact that the applicators are typically arranged in two rows and that “printout” from the applicators in the back row must be delayed in dependence of speed to be correctly deposited in relation to “pixels” deposited from the applicators in the front row. In practice the controlling software can operate with exact positioning at any given time rather than corresponding time and speed.
[0034] Correspondingly the software can account for mutual delay between valves arranged in different rows across the direction of movement between valves in different rows within one and the same applicator, when the applicators 11 have two (as shown) or more rows of valves 14 .
[0035] It should be emphasized that the controlling of the applicator valves can be obtained in many different ways and is as such not limiting. The controlling software can be implemented in many different ways. A preferred variant involves use of bitmap files in which the desired signs, symbols and patterns are coded in, divided in pixels. In addition a printer driver translating such bitmap files to instructions that can be interpreted by the traffic printer is needed, hereunder included the particular delays related to different positions in the direction of movement. The encoding of the software is not described in detail.
[0036] As shown and described, the valves for opening and closing is packer-free and thereby have a more consistent behavior than prior art valves while exhibiting lower friction, thereby allowing rapid opening and closing without use of conventional hydraulic equipment for controlling and closing. Use of valves being equipped with packers would imply larger degree of friction variation from valve to valve and over time, so that the different valves would show a different response on a controlling signal. This would lead to a less even result with respect to mass applied. Valves having a low friction during opening and closing also can be controlled with less force, such as e.g. use of rapid air cylinders or small electric actuators rather than slower, but stronger, oil based hydraulic cylinders.
[0037] Good results over a long period of time often depend upon maintaining clean equipment, especially ensuring that the area around the valve openings 12 does not become clogged by more or less set mass remaining from earlier applications. It is thus important to have reliable procedures for cleaning the valves. For existing, simpler applicators the cleaning has been done manually or immediately before use discharging fresh, hot mass that dissolves and tear away any set mass from earlier applications. The drawback is that these procedures contaminate the equipment and require loss of mass.
[0038] With reference to FIG. 4B , an inventive method of cleaning is disclosed. As shown, the carriage 38 of the traffic printer 37 is hinged so that it can be pivoted about a horizontal axis to an inverted position. Keeping the applicator in the depicted inverted position and having pumped (completely or partly) the viscous mass back to the main container 41 for such mass on the vehicle 40 , a sub-pressure can be set up in the applicators by means of a pump (not shown), and while such sub-pressure connected, the valves of each applicator may be opened and closed quickly, preferably in sequence, so that only one or a few is open at a time. Any partly set mass at the valve orifice then will be sucked into the applicator and mixed with hot, fresh mass making the partly set mass to again become flowable. When the applicators are inverted as depicted, it is also advantageous to perform a visual inspection of the valve orifices and if required manually remove any remains left behind.
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Applicator ( 11 ) for application of a viscous mass ( 31 ) to a surface ( 33 ) comprising a heated chamber ( 32 ) in communication with openings ( 12 ) controlled by valves ( 14 ) allowing dropwise discharge of the viscous mass to the surface. The valves ( 14 ) are non-packed and comprise an outer sleeve ( 15 ) having at least one through opening ( 16 ) in its sleeve wall and valve plug ( 17 ) adapted to the internal surface of the sleeve ( 15 ). The valve plug ( 17 ) is reciprocated by a valve lifter ( 18 ) from a closed position completely sealing the at least one through opening ( 16 ) in the sleeve wall, to an elevated open position exposing at least the lowermost part of the at least one through opening ( 16 ) allowing viscous mass ( 31 ) to pass from the outside of the sleeve ( 15 ) to the inside thereof.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 60/550,595, filed Mar. 4, 2004, the content of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention is directed to polyphenylene polymers and more specifically to branched polyphenylene compositions where the degree of branching is controlled by the selection of mono-, di-, and polyfunctional monomers.
BACKGROUND OF THE INVENTION
[0003] Polyphenylene polymer of various structural types is known. Linear polyphenylenes may be of the rigid-rod type as disclosed in U.S. Pat. No. 5,227,457, semi-rigid as disclosed in U.S. Pat. No. 5,886,130, and may have reactive side groups as disclosed in U.S. Pat. No. 5,625,010 or end groups as disclosed in U.S. Pat. No. 5,670,564, the entire contents of which patents are incorporated herein by this reference. Polyphenylenes may also have a branched (Kovacic et al., Chem. Rev., 1987, 87, 357-379), or hyperbranched (Kim et al., Macromol., 1992, 25, 5561-5572) structure.
[0004] The backbone of polyphenylene polymers is very strong and chemically and thermally inert. If other repeat units or side groups incorporated into polyphenylene are also strong and inert the polymer as a whole will exhibit these properties. The polyphenylene backbone also has a low dielectric constant, low affinity for water, and a high refractive index. These features are desirable for a wide variety of products, including films, fibers, molded and extruded parts, coatings, foams, and composites.
[0005] Linear polyphenylenes suffer from low solubility and are generally difficult to process. Selection of appropriate side groups, as in U.S. Pat. Nos. 5,227,457 and 5,886,130, is essential for practical levels of solubility and for melt processability. Inclusion of branch points also may aid solubility and processability; however, previous branched polyphenylenes either have been prepared from costly and/or unstable monomers (e.g. diethynylbenzenes) or have had uncontrollable levels of branching.
[0006] Hyper-branched polyphenylenes have controlled amounts of branching; however, they are, by design, maximally branched. Hyper-branched polymers have some interesting properties but, unlike linear and lightly branched polymers, do not entangle and are therefore poor film formers and are generally brittle when molded.
[0007] It would be desirable to have polyphenylene polymers with all of the above mentioned positive attributes, including high strength, low dielectric constant, low water uptake, chemical and thermal stability, easy processibility into tough films, fibers, foams, molded parts and the like, and low cost. An improvement in the art would be a polyphenylene material with a controllable degree of branching, thus providing a means for improving solubility and processibility.
SUMMARY OF THE INVENTION
[0008] The current invention is directed to polyphenylene compositions that are moderately to lightly branched, with the degree and type of branching easily controllable by selection of the starting monomers.
[0009] It is well known that unsubstituted polyphenylenes are insoluble and infusible. It is also known that by appending appropriately selected solubilizing side groups to the polyphenylene backbone, both solubility and fusibility are imparted (for example, see U.S. Pat. No. 5,227,457). The particular polymer poly(benzoyl-1,4-phenylene) is an example of a soluble, melt processible, rigid-rod polyphenylene. While the side groups are necessary for solubility and fusibility, they impart some undesired properties, such as an increased dielectric constant (relative to an unsubstituted polyphenylene), altered photophysical properties including a slight yellow color and quenching of fluorescence, and benzophenone-like chemical reactivity. Attempts to reduce or eliminate the undesired properties by preparation of co-polymers like poly(benzoyl-1,4-phenylene-co-1,4-phenylene), which comprises both substituted and unsubstituted phenylene repeat units, are severely limited by rapid loss of solubility as benzoyl groups are removed. For example, poly(benzoyl-1,4-phenylene-co-1,4-phenylene) with half of its repeat units unsubstituted has solubility too low for most practical applications. Low solubility results in polymer precipitation before molecular weights have grown to useful extents.
[0010] We have found that introduction of a limited number of branches can increase the solubility of polyphenylenes. A branched polyphenylene requires fewer solubilizing side groups to impart solubility in organic solvents. Unlike dendrimeric and hyperbranched polyphenylenes, which are poor film formers and are brittle, the branched polymers of the present invention can be cast into freestanding films.
[0011] Thus, one embodiment of the present invention is directed to a polymer having a general formula:
where P is a polyvalent arylene branching repeat unit, D is a divalent arylene repeat unit, M is a monovalent arylene endcapping unit, a, b and c are the relative mole fractions of P, D and M, respectively, and x represents the number of bonds beyond two connecting P to the polymer chain, wherein x≧1.
[0012] In one embodiment, this polymer may additionally comprise solubilizing side chains and/or reactive side chains.
[0013] In still another embodiment, the polymer comprises at least two different monovalent repeat units, at least two different divalent repeat units, and/or at least two different polyvalent repeat units.
[0014] Still another embodiment of the present invention is directed to a polymer having the formula:
wherein B, B′, B″, and B′″ are side groups, which may be the same or different, and which are independently selected from the group consisting of nil, alkyl, aryl, alkaryl, aralkyl, alkyl amide, aryl amide, alkyl ester, aryl ester, alkoxy, polyalkeneoxy, polyphenylene oxide, polyphenylene sulfide, polyvinyl chloride, polyalkylmethacrylate, polyacrylonitrile, polyalkylvinyl ether, polyvinyl alcohol, polyvinyl acetate, perfluoroalkyl, perfluoroalkoxy, polyester, polyamide, polyimide, poly(phenoxyphenyl ketone), amide, ester, ether, sulfone, aryl ketone, alkyl ketone, heteroaryl, and NRR′, p is 0, 1, 2 or 3, q is 0, 1, 2, 3, or 4, r is 0, 1, 2, 3, or 4, and s is 0, 1, 2, 3, 4, or 5.
[0015] In another embodiment of the present invention, this polymer may additionally comprise solubilizing side chains and/or reactive side chains.
[0016] In still another embodiment of the present invention, one or more of the side groups, B, B′, B″, or B′″ is selected from the group consisting of epoxy, ethynyl, phenylethynyl, acetals, acetals from ethylvinylether, acetylenes, acid anhydrides, acrylamides, acrylates, aldehydes, alkyl aldehydes, alkyl halides, alkyl nitriles, aryl aldehydes, aminoalkyl, aminoaryl, aminophenoxy, aminobenzoyl, anilines, azides, benzocyclobutenes, biphenylenes, carbonates, carboxylic acids and their salts, carboxylic acid halides, cyanates, epoxides, fulvenes, halides, heteroaryls, hydrazines, hydroxyls, hydroxylamines, monohydroxyalkyl, hydroxyaryl, hydroxyphenoxy, hydroxybenzoyl, amides, esters, amines, imides, imines, isocyanates, ketals, ketones, maleimides, nadimides, olefins, phenols, phosphates, phosphonates, quaternary amines, silanes, silicates, silicones, sulfonic acids and their salts, sulfonyl halides, tetrahydropyranyl ethers, thioethers, urethanes, vinyl ethers, and vinyls.
[0017] Yet another embodiment of the present invention is directed to a polymer composition prepared by reductive polymerization of at least one aromatic monofunctional monomer having one X group (an endcapper), at least one aromatic difunctional monomer having two X groups (a linear monomer), and at least one aromatic polyfunctional monomer having three or more X groups (a branching monomer), wherein the X groups are selected from the group consisting of chloro, bromo, and sulfonate ester —SO 3 R, wherein R is alkyl, aryl, fluoroalkyl, or fluoroaryl.
[0018] In still other embodiments, the present invention is directed to molding compounds, foams, composites, coatings, polymer blends, optical or opthalmic lenses, dielectric films, extruded parts, molded parts and/or solutions comprising the disclosed polymers and polymer compositions.
DETAILED DESCRIPTION OF THE INVENTION
[0019] All publications mentioned herein are incorporated herein by reference for the purpose of describing and disclosing, for example, the compositions, materials and methodologies that are described in the publications which might be used in connection with the presently described invention. The publications discussed above and throughout the text are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the inventors are not entitled to antedate such disclosure by virtue of prior invention.
[0020] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this invention belongs.
[0021] As used throughout, polyvalent and polyfunctional are considered equivalent terms and are used interchangeably, as are divalent and difunctional, and monovalent and monofunctional.
[0022] A “P-type monomer” or “polyfunctional monomer” is the precursor to a polyvalent or polyfunctional P repeat unit. Similarly, a “D-type monomer” or “difunctional monomer” is the precursor to a divalent or difunctional D repeat unit and an “M-type monomer” or “monofunctional monomer” is the precursor to a monovalent or monofunctional endcapping unit.
[0023] Although any methods, devices and materials similar or equivalent to those described herein can be used in the practice or testing of the invention, the preferred methods, devices and materials are now described.
[0024] In one embodiment of the present invention the polymers have a composition represented by:
where P is a polyvalent branching repeat unit, D is a divalent repeat unit, M is a monovalent endcapping unit, a, b and c are the relative mole fractions of P, D and M respectively, and x is one or more, where x represents the number of bonds beyond two connecting P to the polymer chain. In a preferred embodiment, P, D, and M are all aryl units, and may be comprised of a single aromatic ring, multiple rings, or more than one fused ring.
[0025] In an exemplary embodiment of Structure I, a lightly branched polyphenylene based copolymer which is soluble and processible is synthesized using 1,3,5-trichlorobenzene as P, 1,3-dichlorobenzene and 2,5-dichlorobenzophenone as D, 4-chlorobenzophenone as M, with a=0.02, b=0.96, c=0.02, and x=1. Details of the synthesis of this copolymer are provided below in Example 15.
[0026] In another exemplary embodiment of Structure I, a lightly branched polyphenylene based copolymer which is soluble and processible is synthesized using 1,3,5-trichlorobenzene as P, 1,3-dichlorobenzene and 2,5-dichlorobenzophenone as D, and chlorobenzene as M, with a=0.06, b=0.88, c=0.06, and x=1. Details of the synthesis of this copolymer are provided below in Example 16.
[0027] By “solubilizing group” or “solubilizing side group” is meant functional groups which, when attached as side chains to the polymer in question, will render it soluble in an appropriate solvent system. It is understood that various factors must be considered in choosing a solubilizing group for a particular polymer and solvent, and that, all else being the same, a larger or higher molecular weight solubilizing group will induce a higher degree of solubility. Conversely, for smaller solubilizing groups, matching the properties of the solvent and solubilizing groups is more critical, and it may be necessary to have, in addition, other favorable interactions inherent in the structure of the polymer to aid in solubilization.
[0028] Some or all of the P units, some or all of the D units, and some or all of the M units independently may bear solubilizing side groups, including but not limited to alkyl, aryl, alkyl ketone, aryl ketone, amide, amine, ester, ether, fluoroalkyl, fluoroaryl, heteroaryl, sulfone, and thioether. Non-limiting examples of aryl ketone side groups are benzoyl, 2-naphthoyl, 2-methylbenzoyl(2-toluoyl), —CO-(1,4-phenylene-O-1,4-phenylene-CO-) x -phenyl, and 4-phenoxybenzoyl. Non-limiting examples of heteroaryl side groups are 2-pyridyl, 2-benzoxazoyl, and 2-pyrimidyl. Non-limiting examples of ether side groups are hexyloxy, cyclohexyloxy, phenoxy, —OCH 2 CH 2 OCH 2 CH 2 OCH 3 , polyphenyleneoxy, —O-(-1,4-phenylene-oxy-) x -phenyl, polyethyleneoxy, —O—(—CH 2 CH 2 O—) x —CH 2 CH 3 , and —OCH 2 CF 3 . Side groups may be oligomeric or polymeric.
[0029] In order to prevent crosslinking into an insoluble polymer, the amount of endcaps M should be adjusted to balance the number of branches. The quantity c should be nearly equal to the product of x and a, or xa. Preferably c is within 50% of xa, more preferably within 25% of xa, and even more preferably within 10% of xa.
[0030] One skilled in the art will recognize that in addition to M there may be adventitious endcappers that also limit the molecular weight. In such cases c should be less than xa. If the reactivity of the M type monomer is lower than that of the P and D type monomers it may be advantageous that c be larger than xa.
[0031] To determine optimal ratios of c/a, a series of polymers should be prepared varying the amount of M (i.e., varying c). The MW of the resulting polymers may be measured, for example, by gel permeation chromatography, and the solubility checked in various solvents. If the MW is too high, or solubility too low, then the mole fraction, c, of M should be increased relative to the mole fraction, a, of P.
[0032] Solubility and processibility are also controlled by the relative number of repeat units bearing solubilizing side groups. As discussed above, it may be desirable to limit the number of side groups. A series of test polymer compositions may be prepared having a, b, c, and x, fixed, but varying the fraction of repeat units bearing side groups. For example, a series of five polymers could be prepared, where a=0.1, b=0.8, c=0.1, and x=1, and where 90%, 85%, 80%, 75%, and 70% of the D repeat units bear solubilizing side groups and all remaining monomers units are unsubstituted. A second series of polymers may be prepared based on the solubility of the first series, for example, if the polymer in the first series having 85% side groups was sufficiently soluble, but 80% was not, a new series with 85%, 84%, 83%, 82%, and 81% substituted would be prepared and tested. If the polymer with 70% side groups was sufficiently soluble, then a new series with 65%, 60%, 55%, and 50% side groups would be prepared and tested. These examples are for illustrative purposes only. One could experimentally test any number of polymers having various values for a, b, c, and x to determine the optimum degree of branching, solubility, and molecular weight for desired properties.
[0033] It may be desirable to have 100% of D repeat units substituted with solubilizing side groups. It may also be desirable to have 100% of P, D, and/or M repeat units substituted with solubilizing side groups.
[0034] The side groups may also be reactive side groups or solubilizing reactive side groups, as disclosed for the linear polyphenylenes of U.S. Pat. Nos. 5,625,010 and 5,670,564 referred to above. In this embodiment the branched polymers could react further, for example, to cure on the application of heat or to form graft copolymers on the addition of a monomer or polymer reactive with the reactive side groups.
[0035] Non-limiting examples of reactive side groups include acetals, acetals from ethylvinylether, acetylenes, acetyls, acid anhydrides, acids, acrylamides, acrylates, alcohols, aldehydes, alkanols, alkyl aldehydes, alkyl ketones, amides, amines, alkyl halides, anilines, aryl aldehydes, aryl ketones, azides, benzocyclobutenes, biphenylenes, carbonates, carboxylates, carboxylic acids and their salts, carboxylic acid halides, carboxylic anhydrides, cyanates, cyanides, epoxides, esters, ethers, formyls, fulvenes, halides, heteroaryls, hydrazines, hydroxylamines, imides, imines, isocyanates, ketals, ketoalkyls, ketoaryls, ketones, maleimides, nadimides, nitriles, olefins, phenols, phosphates, phosphonates, quaternary amines, silanes, silicates, silicones, silyl ethers, styrenes, sulfonamides, sulfones, sulfonic acids and their salts, sulfonyl halides, sulfoxides, tetrahydropyranyl ethers, thioethers, urethanes, vinyl ethers, vinyls and the like. In some cases, the functional side groups are capable of reacting with each other.
[0036] In another embodiment of the present invention, branched polyphenylenes are formed by the copolymerization of monomers, at least one selected from each of the three groups Group P, Group D, and Group M as shown below:
where X is selected from —Cl, —Br, and sulfonate esters, which sulfonate ester is preferably triflate (trifluoromethylsulfonate) ester, i is 3 or more, X's may be on any position on a ring or fused ring or on any ring of a multi-ring system, except that X may not be ortho to another X, the R's are selected independently from the following:
aryl ether, and alkyl ether, o is 0 (no side group) or 1 or more, such that each hydrogen on the ring may be replaced by an R group, Ar is C6 to C24 aryl or heteroaryl, E is divalent —O—, —S— or >NR′, the dotted semicircle represents one or more fused aromatic rings, A and B are independently nil, or divalent groups >CR′R′, —O—, >NR′, —S—, >CO, —CR′R′CR′R′—, or >CF 2 , and R′ are independently H, alkyl, or aryl. Adjacent rings, either on the same repeat unit or neighboring repeat units may be bridged by the side groups. Side groups may also be selected from those listed in U.S. Pat. Nos. 5,227,457, 5,565,543, 5,625,010, 5,654,392, 5,670,564, and 5,886,130, all of which are incorporated herein in their entirety by this reference.
[0037] Note that more than one type of repeat unit can be included from any or all of the groups P, D, and M. A non-limiting example of a composition having more than one D type repeat unit is the aforementioned poly(benzoyl-1,4-phenylene-co-1,4-phenylene) polymer, which could be prepared to include P-type branching monomers according to the present invention. In one embodiment, the invented polymer contains more than one P-type repeat unit. Each P monomer need not have equal values of x, for example, a polymer could contain a fraction of P-type monomers having three bonds to the backbone (x=1) and a second fraction of P-type monomers having four bonds to the backbone (x=2).
[0038] The side groups may be added or modified after polymerization. For example, a phenoxy side group may be brominated to give a bromophenoxy side group. Note that all of the phenoxy side groups need not be brominated; the polymer may be partially brominated. The bromophenoxy side group may be treated with phenylacetylene and a Pd/Cu catalyst to give a phenylethynylphenoxy side group. The phenylethynylphenoxy side group is a reactive side group and cures on heating to crosslink the polymer. The polymers of the instant invention may be prepared by reductive coupling of haloaromatics selected from substituted or unsubstituted 1,3,5-trihalobenzene, 1,3-dihalobenzene, 1,4-dihalobenzene, and monohalobenzene. Halo as used in the term haloaromatics means Cl, Br, I, tosylate, mesylate, triflate, sulfate ester, preferably Cl.
[0039] The preferred method of polymerization is reductive polymerization with zinc dust as reducing agent and a nickel catalyst as disclosed in U.S. Pat. Nos. 5,227,457, 5,565,543, and 5,654,392, referred to above.
[0040] The nickel catalyst may be derived from nickel chloride or nickel bromide and a monodentate ligand, preferably triphenylphosphine (TPP), although other nickel complexes may be used. Where the polymers of the instant invention are prepared by nickel catalyzed coupling, it is preferred that at least one of the side groups on monomers that bear side groups are electron withdrawing groups.
[0041] The polymers of the present invention also may be prepared by Suzuki coupling of mono, di, and polyhalo monomers with diboronic acid or ester monomers, with optional mono or polyboronic acid or ester monomers. Suzuki coupling also may be conducted with mono, di, and polyboronic acid or ester monomers with dihalo monomers, with optional mono or polyhalo monomers. Other methods of aryl coupling, such as Stille coupling, Miyura coupling, and Negishi coupling, may also be applied to prepare the branched polyarylenes of the present invention. Unlike nickel coupling, the Suzuki and similar methods do not require electron withdrawing side groups.
[0042] The polymers of the present invention are useful for applications where the properties of low dielectric constant, low moisture uptake, melt and solvent processibility, and excellent chemical and thermal stability are desired. Such applications include fibers, films, coatings, molded parts, foams, adhesives, composite matrix resins, additives for other polymers, and the like. Specific applications include printed wiring boards, dielectric materials for integrated circuits, molding compounds for electrical connectors, lead frames, switches and the like, molding compounds for automotive applications, molding compounds for orthopedic fixtures, tubing, catheters, and other devices for biomedical or dental applications, optical polymers, opthalmic polymers, honeycomb material for structural parts for aircraft, ships, trucks, and trains, scratch resistant coatings for windows, glazings, and displays, molding compounds for gears, bearings, linkages, and mechanical parts for industrial equipment and consumer appliances and electronics, pipe, tubing, rod, and profile for general manufacturing, and additives to modify the glass transition temperature, hardness, solvent resistance, stiffness, modulus, flammability, and toughness of other polymers and resins.
[0043] The polymers of the present invention also have use as materials for electroluminescent devices and as luminescent materials in general. Because of the extended polyphenylene chains, the compositions disclosed herein will fluoresce unless side groups with fluorescence quenching properties are selected. The branched polyphenylenes will be good electron and hole transport polymers. Electron transport may be enhanced through selection of side groups that are easily and reversibly reduced, including, but not limited to, groups such as oxadiazole, perfluorophenyl, pyridyl, pyrazinyl, benzoxazole, benzthiazole, benztriazole, and benzothiadiazole. Hole transport may be enhanced through selection of side groups that are easily and reversibly oxidized, including, but not limited to, groups such as carbazole, triarylamine, naphthylamines, and thiazine. Electron and hole transport polymer may be used as electron and hole transport layers in Organic Light Emitting Diodes (OLEDs) and Polymer OLEDs (POLEDs). Because of their fluorescence, the polymers of the present invention may be used as light emitting layers in OLEDs and POLEDs. They may be used as the pure polymer or doped with other fluorescent or phosphorescent materials.
[0044] The polymers of the present invention also may be used as materials for Proton Exchange Membranes (PEMs). PEMs have applications in fuel cells.
EXAMPLES
Example 1
Activation of Zinc
[0045] Commercially available 325 mesh zinc dust (100 g) was stirred in 100 ml methanol using an overhead stirrer, under nitrogen. A solution of 2 ml conc. HCl in 18 ml methanol was added slowly over about 20 min until the dull gray color of the suspended zinc began to brighten. The mixture was then filtered on a glass frit filter and dried under a stream of nitrogen. The activated zinc powder should be sieved before use to remove any lumps.
Example 2
Poly(1,4-(benzoylphenylene) 0.92 -co-1,3,5-phenylene 0.4 -co-phenylene 0.4 )
[0046] A 100 ml round bottom flask was loaded with bis-triphenylphosphine nickel dichloride (0.593 g, 0.906 mmol), triphenylphosphine (3.21 g, 14.04 mmol), activated zinc dust (3.00 g, 45.92 mmol), sodium iodide (0.73 g, 4.86 mmol) and N-methylpyrrolidinone (NMP) (45.33 ml) in an inert atmosphere box. The flask was closed and brought out of the inert atmosphere box. While maintaining the flask under an inert atmosphere, monomers were added in the following amounts: 8.09 g (32.2 mmol) of 2,5-dichlorobenzophenone, 0.254 g (1.4 mmol) of 1,3,5-trichlorobenzene, and 0.158 g (1.4 mmol) of chlorobenzene. The mixture exothermed and cooling was applied to keep the temperature below 92° C. The mixture became viscous in about 10 min. When the exotherm subsided the flask was heated to 65° C. with stirring for 2 hr. The mixture was cooled to room temperature, stirred with ethanolic HCl, and washed with hot ethanol and then hot acetone. The resulting white solid was filtered and dried. Gel permeation chromatography (GPC) indicated a weight average molecular weight M W =296,156, number average molecular weight M N =89,251, and polydispersity=3.3, against polystyrene calibration standards.
Examples 3-14
[0047] The following compositions were prepared using the same general procedure as in Example 2, where monomer D1 is 1,3-dichlorobenzene, monomer D3 is 1,4-dichlorobenzene, monomer D4 is 2,5-dichlorobenzophenone, monomer P1 is 1,3,5-trichlorobenzene, and monomer M1 is chlorobenzene. Solubility was tested in hot NMP. The values in columns 2 through 6 of the table indicate the mole percent of the particular monomer added to the reaction flask. The total amount of monomer was kept nearly constant while the relative monomer amounts were varied.
Ex. D1 D3 D4 P1 M1 Comments 3 96 4 Insoluble 4 90 5 5 Soluble, melts, M W 75,386 5 60 30 5 5 Insoluble 6 80 10 10 Soluble, melts, M W 71,469 7 70 15 15 Soluble, M W 237,599 polymodal PDI 29 8 90 5 5 Soluble, melts, M W 5,574 9 50 25 25 Soluble, M W 371,154, brittle film 10 30 35 35 Insoluble 11 10 30 30 30 Insoluble, appears to melt 12 20 40 40 Insoluble 13 10 45 45 Insoluble 14 80 8 12 Soluble, M W 85, 162
Example 15
[0048] A 250 ml round bottom flask is loaded with bis-triphenylphosphine nickel dichloride (1.05 g), triphenylphosphine (6.35 g), activated zinc dust (5.7 g), sodium bromide (0.85 g), and N-methylpyrrolidinone (NMP) (120 ml) in an inert atmosphere box. The flask is closed and brought out of the inert atmosphere box. 1,3-dichlorobenzene (2.3 g), 2,5-dichlorobenzophenone (19.7 g), 1,3,5-trichlorobenzene (0.36 g), and 4-chlorobenzophenone (0.43 g) are added and the flask is maintained under an inert atmosphere. Sufficient cooling is applied to maintain the temperature of the exothermic reaction at approximately 80° C. to 85° C. After about 15 minutes the mixture becomes viscous. When the exotherm subsides the flask is heated to 65° C. with stirring for 2 hr. The mixture is cooled to room temperature, stirred with ethanolic HCl, and washed with hot ethanol and then hot acetone. The resulting white solid is filtered and dried. The product is a lightly branched polyphenylene based copolymer which is soluble and processible.
Example 16
[0049] A 250 ml round bottom flask is loaded with bis-triphenylphosphine nickel dichloride (1.02 g), triphenylphosphine (6.40 g), activated zinc dust (5.38 g), sodium bromide (0.84 g), and N-methylpyrrolidinone (NMP) (120 ml) in an inert atmosphere box. The flask is closed and brought out of the inert atmosphere box. 1,3-dichlorobenzene (1.40 g), 2,5-dichlorobenzophenone (18.6 g), 1,3,5-trichlorobenzene (1.03 g), and chlorobenzene (0.64 g) are added and the flask is maintained under an inert atmosphere. Sufficient cooling is applied to maintain the temperature of the exothermic reaction at approximately 80° C. to 85° C. After about 15 minutes the mixture becomes viscous. When the exotherm subsides the flask is heated to 65° C. with stirring for 2 hr. The mixture is cooled to room temperature, stirred with ethanolic HCl, and washed with hot ethanol and then hot acetone. The resulting white solid is filtered and dried. The product is a lightly branched polyphenylene based copolymer which is soluble and processible.
[0050] While this invention has been described in detail with reference to certain preferred embodiments, it should be appreciated that the present invention is not limited to those precise embodiments. Rather, in view of the present disclosure which describes the current best mode for practicing the invention, many modifications and variations would present themselves to those of skill in the art without departing from the scope and spirit of this invention. In particular, it is to be understood that this invention is not limited to the particular methodology, protocols, and reagents described as such may vary, as will be appreciated by one of skill in the art. The scope of the invention is, therefore, indicated by the following claims rather than by the foregoing description. All changes, modifications, and variations coming within the meaning and range of equivalency of the claims are to be considered within their scope.
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Branched polyarylene polymers are provided comprising monovalent endcappers, divalent linear units, and polyvalent branching units. The composition of the polymers is controlled by adjusting the ratio of the three types of monomers.
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DESCRIPTION
The present invention relates to a package, particularly but not exclusively for packs of sanitary products, for example, plastics packs for products such as babies' disposable nappies.
Plastics bags are becoming the most widespread type of pack for sanitary products such as babies' disposable nappies and are particularly suitable for compressed products, that is, products which have been subjected to a certain degree of compression before insertion in the bags in order to obtain smaller packs which occupy less space and use less raw material.
Once packed, the bags are package in corrugated cardboard boxes for despatch; the cardboard box simplifies the handling and transportation of the bags and also constitutes a sales unit for the product.
However, cardboard boxes represent a considerable quantity of material which has to be purchased and stored by the user who uses it to pack products and which, once the goods have arrived at their destination, is then generally disposed of by the purchaser.
Moreover, when bags of disposable nappies are packaged in cardboard boxes the space inside the boxes cannot be fully utilised because of the tolerances imposed by the usual automatic mechanical boxing systems generally used.
The problem of the utilization of space is made even more important by the increasingly widespread use of pallets of standard dimensions for the transportation of the boxes, in response to the requirements of large distribution and sales organisations.
The object of the present invention is to improve the characteristics of packages, for example, for plastics packs of sanitary hygiene products, such as babies' disposable nappies, by means of a package which avoids the use of corrugated cardboard boxes and which has the characteristics recited in the followwing claims.
Further characteristics and advantages of the invention will become clear from the following description, given purely by way of non-limiting example with reference to the appended drawings, in which:
FIG. 1 is a perspective view of a conventional package of four plastics packs of sanitary hygiene products which are housed in a corrugated cardboard box with the box shown transparently to show its contents more clearly,
FIG. 2 is a perspective view of the same four packs, packaged according to the present invention,
FIG. 3 shows a portion of the adhesive tape used to form the package according to the present invention,
FIG. 4 is a view of a roll of adhesive tape from which the portion shown in FIG. 3 can be formed,
FIGS. 5-9 are perspective views of a corresponding number of alternative configurations of a package of four packs formed according to the present invention,
FIG. 10 is a perspective view of the arrangement of corrugated boxes of the type illustrated in FIG. 1 on a pallet,
FIG. 11 is a perspective view of the arrangement of packages formed according to the present invention on a pallet of the same type, and
FIGS. 12-19 show a perspective schematic view of different configurations of a package according to the invention.
The package of the present invention will be described herein, by way of example, in relation to its use for plastics packs of sanitary products such as babies' disposable nappies; in this connection, it should be pointed out that the following description relates to a preferred embodiment of the present invention; it should be understood, however, that the present invention is also applicable to packs of other types, such as containers made of semi-rigid material, for example light card, or of different shapes.
By way of reference, FIG. 1 shows a conventional package constituted by a corrugated cardboard box 1 containing four plastic packs 2 of disposable nappies.
The packs 2 are of the type commonly available commercially and generally comprise a handle 3 at the top to enable the user to carry them.
FIG. 1 shows one of the possible configurations with the four packs 2 disposed in the two superposed layers within the box 1.
To enable the packs 2 to be inserted by packaging machines, however, some of the space in the box is not filled; Fig. 1 shows the spaces 4 left between the packs 2 and the walls of the box 1 along its longer sides.
FIG. 2 shows the same packs 2 packaged according to the present invention; the packs are placed one beside the other in a single row with their longer sides next to each other in a manner such that their eight shorter sides 5, four adjacent sides at each end, the two outer longer sides 6 of the two end packs and, finally, the upper and lower faces of the packs face outwardly.
In the configuration shown, the packs are bound together by means of at least four pieces of adhesive tape 7 applied, two on each side and parallel to each other, to the two shorter sides 5 of each pack, forming a package which takes up less space than the cardboard box 1 although it contains the same number of packs 2.
The package can easily be picked up and carried by hand by being gripped, for example, by the handles 3 of the two end packs; the handle 3 of each individual pack 2 can preferably support the weight of the entire package.
On each of the two ends of the package formed by the four adjacent shorter sides 5 of the packs 2, one of the two pieces of adhesive tape 7 is positioned high up, a short distance from the upper edges of the shorter sides 5 and parallel thereto, and the other piece is positioned low down, a short distance from the lower edges of the sides 5.
In general, at least one piece of adhesive tape 7 is positioned within the upper halves of the adjacent shorter sides 5 on each side of the package and at least one further piece is positioned within their lower halves; the portion of each shorter side 5 which is between the upper tape and the lower tape is preferably tall enough to include an opening system for the pack of nappies such as, for example, that described in patent application IT 67217 A/90.
In any case the widths of the pieces of adhesive tape 7 should be such that the tapes cover in total at least 20% of the surfaces of the shorter sides 5 of the packs 2.
The two ends of each piece of adhesive tape 7 also extend partially along two outer longer sides 6 in order to improve the grip of the tape and hence the stability of the group of packs.
Each end of each piece 7 has an adhesive-free region 8 which can easily be gripped in order to start the removal of the tape and thus separate one or more packs 2 from the group.
The adhesive tape of which the pieces 7 are formed must have certain characteristics in relation to thr substrate constituting the wrappers of the packs of nappies to which it is to be applied, which is typically of printed plastics, for example, polyethylene film.
In particular, the tape should not have a tendency to leave some of the adhesive on the substrate to which it is applied during the removal of the tape form the wrapper of the pack and should not give rise to relative slippage between the tape and the substrate during thre life of the package; these characteristics may be expressed in terms of the creep strength of the adhesive tape in relation the substrate.
The degree of tackiness of the adhesive tape, which can be measured as the peel strength of the adhesive tape in relation to the substrate, should be such as to confer good stability to the group of packs under normal handling and transportation stresses but, at the same time, must enable the tapes to be removed easily when the individual packs are separated from the package; in any case, the peel strength of the adhesive tape should be less than the strength of the substrate to which it is applied so that, when the adhesive tape is removed, the substrate which is made, for example, of the polyethylene film typical of nappy packs, is not torn.
Moreover, the tape must have good long-term stability to ensure constant peel strength and shear strength throughout the life of the package, which includes the periods of time during which it is transported and stored both by the producer and by the customer.
Finally, the tape should have a tensile strength such that it can withstand the stresses to which it may be subjected during the life of the package without breaking.
The shear strength was measured by the PSTC7 Test, Method A for measurement at ambient temperature and Method C for measurement at 50° C., which are described in the Ninth Edition of "Test Methods for Pressure Sensitive Tapes" published by the Pressure Sensitive Tape Council, Suite 201, 104 Wilmot Road, Deerfield, Ill., U.S.A., and modified as follows.
For both the methods a steel support plate was used, and was covered by a layer made of the same material as the packs 2, typically a polyethylene film 80 microns thick, which had the same dimensions as the plate and was fixed thereto.
The roller used to press the test sample onto the substrate weighed 2 kg and the weight used for the test also weighed 2 kg.
The sample of adhesive tape used for the test was 25.4 mm (1 inch) wide and was stuck to the substrate so as to cover an area of 25.4×25.4 mm 2 (1 square inch).
The test evaluated the ability of an adhesive tape to remain adhering to the substrate under a load applied parallel to the surface of the tape.
One end of the adhesive tape was fixed to the test surface which was disposed vertically, and a weight was applied to the other end; the time required to remove the adhesive tape completely from the test surface under the load exerted by the weight was measured.
The peel strength was evaluated by the "FINAT Test Method No. 2" (FTM2) described in "FINAT Pressure Sensitive Laminates Suppliers and Users Technical Manual", 1985 edition, published by FINAT Pressure Sensitive Technical Committee and available from FINAT Secretariat, Laan Copes Van Cattenburch 79, 2585 EZ, The Hague, NL and modified as follows.
The glass support plate used for the test was replaced by a 50×160 mm plate 6 mm thick formed by two 3 mm wood fiber panels (faesite) covered on one side with a layer of plastics laminate with a smooth, opaque outer finish, the plate as a whole showed the laminate on both faces.
A layer, having the same dimensions as the plate and made of the material of which the packs 2 are formed, typically a polyethylene film 80 microns thick, was fixed to one face of the plate.
The peel strength of the adhesive tape was tested on the surface of the sheet material fixed to the plate.
The force required to remove and adhesive tape previously applied to a test surface was measured, with an angle of 90° between the direction of the force and the surface.
An adhesive tape from which to form the pieces 7 having the desired characteristics may be constituted by a substrate film of polypropylene 35 microns thick suitably rendered adhesive so that it has a peel strength of between 0.2 N/cm and 2.5 N/cm, preferably between 0.8 N/cm and 1.6 N/cm, and a shear strength of at least 500 min measured at ambient temperature and at least 50-60 minutes measured at 50° C., in relation to the substrate to which it is stuck.
The adhesive tape from which the pieces 7 are formed may be transparent so that, once applied to the packs 2 it does not conceal the surfaces of the packs, which are generally printed.
It can be seen from FIG. 3 that a bar code 9 for the automatic identification of the product during handling and an alphanumeric code 10 for immediate visual identification can preferably be applied to each piece of adhesive tape 7; the codes can be used advantageously both by the manufacturer and by the customer.
In order to prevent the automatic reading of the bar code from being made difficult by the underlying printing on the pack, the portion 11 of adhesive tape corresponding to the bar code may be made opaque, for example, it may have a black background.
Each piece of adhesive tape 7 having the preferred characteristics and also including the adhesive-free regions 8 and the codes 9 and 10 may be formed from a continuous tape wound in the form of a roll 12, as shown in FIG. 4.
FIGS. 5-9 show some alternative configurations of the package formed according to the present invention; the numerals used in these drawings refer to the same elements as in FIG. 2.
FIG. 5 shows a package similar to that of FIG. 2 with two pieces of adhesive tape 7 wound all the way around the shorter sides 5 and the longer sides 6 of the packs 2 and positioned in a similar manner to the four pieces of the configuration shown in FIG. 2.
FIGS. 6 and 7 show a further two alternative configurations of the package of the present invention; in FIG. 6, the shorter sides 5 of the four packs are bound together by a single piece of adhesive tape 7 at each end, the tape also extending partially on the longer sides 6 and, in the configuration of FIG. 7, a single piece of adhesive tape 7 is wound all the way around the four packs 2 on their shorter sides 5 and on their longer outer sides 6. In both cases each piece of adhesive tape 7 is positioned in the center of the adjacent short sides 5, having such a height as to cover preferably at lease 40% of the total surface area of the shorter sides 5 of the packs 8.
In FIGS. 8 and 9, the upper and lower faces of the four packs 2 are bound together in a configuration which is particularly suitable for packs 2 each having a handle 3 with dimensions such that it extends solely on the central portion of the upper face, for example, of the type which is applied to the pack rather than being formed integrally therewith, as shown in the drawings.
FIG. 8 shows the four packs 2 joined together by two pieces of adhesive tape 7 fixed to the upper faces and by a further two fixed to the lower faces, the pieces also extending partially over the outer longer sides 6.
The pieces of adhesive tape 7 are generally positioned within the third of each upper and lower face which is adjacent the respective shorter side 5, in any case without interfering with the handles 3 disposed on the top; in partivular, as shown in FIGS. 8 and, the pieces of adhesive tape 7 are offset towards the shorter edges of the upper and lower faces and are parallel thereto.
In all the alternative configurations shown in FIGS. 5-9, each end of each piece 7 has an adhesive-free region 8 which can be gripped in order to start the removal of the tape and thus to separate one or more packs 2 from the group. If the piece or pieces of adhesive tape 7 are wound all the way around the packs 2, one end of each piece 7 may be superposed on the opposite end, as shown, in particular, in FIGS. 5, 7 and 9 which show a single adhesive-free region 8 for each piece 7, on one of the two outer longer sides 6; alternatively, the two ends may be spaced apart and thus both be visible when the package is still intact.
The package according to the present invention can, to advantage, be used with pallets of standard dimensions, the use of which is becoming increasingly widespread at the request of the large distribution and sales organisations.
FIGS. 10 and 11 show two different loading configurations on a pallet 13 of the same type with standard dimensions for conventional packages with corrugated cardboard boxes such as that shown in FIG. 1 and for packages according to the present invention, such as that shown in FIG. 2, respectively.
The packages according to the present invention are disposed on the pallet 13 in superposed layers with a sheet of corrugated cardboard 14 disposed between two layers approximately half-way up the whole stack in order to stabilise the stack; a second sheet 15 is preferably added on toop of the last layer.
In both cases, the load may be surrounded by a sheet of extensible plastics of the type commonly used for covering and protecting loads on pallets.
By avoiding the use of cardboard boxes, the package according to the present invention eliminates all the costs connected with the provision and use of such boxes and thus represents and advantage both for the manufacturer and for the customer who no longer has to open and empty the boxes in order to make the products accessible or finally to dispose of the empty boxes; the saving of space also achieves and overall reduction in storage and distribution costs.
The new package itself constitutes a sales unit for the product and, moreover, by virtue of the handles 3 of the individual packs 2 and the fact that the product can be recognized more readily than with conventional cardboard boxes, it can be dealt with more easily during the manual handling which is usually carried at the customers premises.
Moreover, the packages can also be positioned on sales shelves as they are without the need to separate the individual packs, the purchaser thus being left to take out the individual packs 2 directly by removing the piece or pieces of adhesive tape 7 which keep it bound to the package, thus being able to separate a single pack 2 at a time, leaving the rest of the package intact.
The products may also be taken to the point of sale directly on the pallets, once the extensible plastics covering sheet has been removed.
In the embodiments illustrated, the flexible plastics packs have dimensions of 145×420×240 mm (width×length×height) and each contains 36 disposable elasticated nappies of a type commonly available on the market which, in the extended configuration, measure 535×350 mm.
The packs are housed in corrugated cardboard boxes with dimensions of 340×420×520 mm and in packages according to the present invention with dimensions of 580×420×240 mm, each bound together by four pieces of adhesive tape 800 mm long and 60 mm wide; the pallets have standard dimensions of 1200×800 mm.
In the first case there are eighteen cardboard boxes on the pallet in three layers of six with a total height of 1560 mm, leaving an unused empty space in the center shown by shading in FIG. 10; in the second case, there are twenty-eight packages formed according to the present invention, arranged on the pallet in seven layers of four, with a total height of 1700 mm, which is slightly greater than in the first case but within the size limits fixed conventionally for loads on pallets; the saving of space thus achieved is about 50%.
Naturally this saving relates to the configuration of the embodiment illustrated.
In any case, although the dimensions of the individual packs 2 vary, for example, according to the different measurements of nappies and the number of packs which make up the package of the present invention, there will always be a saving of space, greater or less than that shown in the example, in comparson with corresponding conventional packages in cardboard boxes.
Naturally, the principle of the invention remaining the same, the details of construction and forms of embodiment may be varied widely with respect to those described and illustrated, without thereby departing from the scope of the present invention.
FIGS. 12, 13 and 14 show a package according to the invention consisting of two polyethylene diaper bags 23,25. In the package of FIGS. 12 and 13, two longitudinal side faces 27,27' of the bags 23,25 are contiguous. The bags are held in a fixed position by adhesive tape 35, which is sufficiently strong to enable the bags 25 and 23 to be carried, or otherwise transported, as a single unit. The tape 35 extends from the lateral side face 29 of bag 25, across the transverse side faces 31 and 33 of both bags 25 and 23 to the lateral side face 29' of bag 23. In this way, relative movement of bags 23 and 25 is prevented, both in a direction parallel to the plane of side faces 29,29' as well as in a direction perpendicular to the plane of the side faces 29,29'.
In the package according to FIG. 14, the bags 23,25 are aligned in their longitudinal direction. Two tapes 35,35' provide for a stable connection of the bags that can be easily undone.
In the package according to FIGS. 15 to 18, a plurality of bags is connected to form a single package by means of tape 35. The tape 35 can comprise a number of separate tape members, or can consist of one or more single strips that completely encircle the package. In the package according to FIG. 19, a multiplicity of bags 25, 23 is configured and connected for shipment on a pallet of predetermined dimensions.
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A package for packs, for example packs of absorbent articles, each pack comprising a plurality of such absorbent articles and a wrapper of flexible material with a carrying handle at the top. The package comprises a plurality of packs disposed side by side and fixed together with adhesive tape, the adhesive tape being detachable without tearing the flexible material. Each handle is capable of supporting the weight of the entire package.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present application relates to integrated circuits, and more particularly to configuring the performance of integrated circuits.
[0003] 2. Description of the Related Art
[0004] Performance of integrated circuits continues to improve along with semiconductor manufacturing yield rates. The pricing of integrated circuits is generally based on market demand as well as the speed or performance ratings of the integrated circuit. Additionally, the anticipated production yield affects pricing as well as customer commitments. For example, FIG. 1 a, labeled Prior Art, shows is a generalized illustration of a distribution of market demand of processors corresponding to certain processor clock speed. In this illustration, a majority of the processors produced demonstrate clock speeds that are ±5% of the predicted speed, with fewer processors demonstrating clock speeds that are ±10% of predicted speed, and fewer yet that demonstrate clock speeds that are ±15% of predicted speed. Processors that demonstrate ±5% clocks speed variance are typically labeled at the nominal rated speed. This nominal speed is priced accordingly and often a processor manufacturer will make quantity commitments to supply a certain number of processors at this performance level for a predefined price. Processors demonstrating clock speeds that are 10-15% higher than predicted speeds are sorted or graded (e.g., binned) according to their rating and labeled appropriately. These higher performing processors are typically sold at a higher price point. Additionally, as with the nominal speed processors, a processor manufacturer will make quantity commitments to supply a certain number of processors at this performance level for another predefined price. Similarly, those processors that demonstrating clock speeds that are 10-15% lower than predicted speeds are likewise binned according to their lower rating and typically sold at a lower cost, or possibly, judged to not be marketable and discarded.
[0005] FIG. 1 b, labeled Prior Art, is a generalized illustration of an example actual yield rate as compared to market demand commitments as well as an example of how the processors might be sorted according to predefined customer commitments. In this illustration, the actual production yield was better in both quantity and performance when compared to market demand. However, because customer commitments were made for certain quantities at certain performance levels, some of the processors that yielded at a higher performance level might be “downgraded” such that the higher performance processors are sorted and binned at a lower performance level.
[0006] When the processors are binned, one of the final steps of the processor fabrication process is locking the processor to a particular performance level. This locking is typically performed by blowing fuses within the processor so that the processor is then configured to perform a certain number of operations within a predefined time period.
[0007] While certain segments of the market have requirements for higher performing products and are willing to pay for them, other segments may not have a current need but might in the future, especially if their requirements change. For example, a computer system may be placed in service for general business use and might not need the fastest processor. At a later time, the same computer system may be repurposed for use for editing digital content, which typically requires a higher performing system. As another example, a newer version of an operating system may require a faster processor to deliver the same level of performance as the current processor with the earlier version of the operating system. Currently, these situations might require the purchase of a new computer system or upgrading the processor to a higher performing version. New computer systems can be costly and the replaced computer system is often reassigned or retired from service. If the processor is upgraded the cost of a new processor is incurred along with the time and effort required for the upgrade.
[0008] Predicting when additional performance will be required is difficult and can result in unnecessary cost. For example, business customers are often compelled to purchase the performance they might need in the future at a premium today, whether it is eventually needed or not.
[0009] In view of the foregoing, there is a need for delivering processors and other integrated circuits that have dormant performance that can activated and paid for on an as-needed basis.
SUMMARY OF THE INVENTION
[0010] The present invention provides a method and system to remotely configure performance in a processor or other integrated circuit device in return for commensurate consideration.
[0011] For example, a general purpose computer can be purchased with a processor that is capable of operating at a speed of 3 GHz, yet initially operates at a clock speed of 2 GHz. At a later date, additional performance can be purchased to remotely and non-intrusively unlock the processor's dormant performance capabilities to deliver a clock speed of 2.5 Ghz. The metrics for the purchase of the unlocked performance are predetermined by the manufacturer or supplier intermediary, and can be a one-time for perpetual use of the higher performance thereafter, for a limited period of time (e.g., 90 days), or for limited peak usage not to exceed a predetermined percentage of overall non-idle cycles.
[0012] In one embodiment, the invention relates to a method for manufacturing an integrated circuit which includes fabricating the integrated circuit, sorting the integrated circuit to a second performance level, and locking the integrated circuit to operate at the second performance level when manufacturing the integrated circuit. The integrated circuit is fabricated to operate at a first performance level and configured to be unlocked to operate at the first performance level.
[0013] In another embodiment, the invention relates to an apparatus for manufacturing an integrated circuit which includes means for fabricating the integrated circuit, means for sorting the integrated circuit to a second performance level, and means for locking the integrated circuit to operate at the second performance level when manufacturing the integrated circuit. The integrated circuit is fabricated to operate at a first performance level and configured to be unlocked to operate at the first performance level.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIGS. 1 a and 1 b, generally referred to as FIG. 1 and labeled Prior Art, show distributions and yield rates of integrated circuits.
[0015] FIG. 2 shows a flow chart of the operation of a system for enabling and configuring integrated circuit performance.
[0016] FIG. 3 shows a block diagram of a computer system having an integrated circuit performance monitor module.
[0017] FIG. 4 shows a block diagram of a processor having a configurable performance module.
[0018] FIG. 5 shows a block diagram of the configurable performance module.
[0019] FIG. 6 shows a block diagram of the operation of the integrated circuit performance monitor module.
DETAILED DESCRIPTION
[0020] Referring to FIG. 2 , a generalized flow chart of the operation of a system for enabling increased performance and remotely increasing performance in an integrated circuit is shown. When the system starts operation, integrated circuits (ICs) are manufactured at Step 212 and their performance is tested at Step 214 . Based on their tested performance characteristics, ICs are then binned at Step 216 with their corresponding price points being determined at Step 218 . Initial processor performance levels are set at Step 220 and the IC is placed into service at Step 222 .
[0021] Once placed into service, a request for additional performance is received at Step 230 . If the request is accepted at Step 232 , then consideration is obtained in Step 240 and the new level of performance is set at Step 220 .
[0022] If the request is denied at Step 232 , then the operation of the system for enabling increased performance and remotely increasing performance completes.
[0023] Referring to FIG. 3 , a block diagram of an exemplary computer system 300 is shown. The computer system 300 includes a processor 302 , input/output (I/O) control device 304 , memory (including volatile random access memory (RAM) memory 306 and non-volatile memory 307 ), communication device 313 (such as a modem) and a display 314 . The processor 302 , I/O controller 304 , memory 306 and communication device 313 are interconnected via one or more buses 312 . The non-volatile memory 307 may include a hard disk drive 309 either or both of the memories 306 , 307 may be integrated with or external to the computer system 300 . Of course, it will be appreciated that other device configurations may also be used for the processor 302 , memory 306 , 307 , display 314 and communication device 313 . For clarity and ease of understanding, not all of the elements making up the computer system 300 are described in detail. Such details are well known to those of ordinary skill in the art, and may vary based on the particular computer vendor and microprocessor type. Moreover, the computer system 300 may include other buses, devices, and/or subsystems, depending on the implementation desired. For example, the computer system 300 may include caches, modems, parallel or serial interfaces, SCSI interfaces, network interface cards, and the like.
[0024] The I/O control device 304 is coupled to I/O devices 305 , such as one or more USB ports, a keyboard, a mouse, audio speakers, etc. The I/O control device 304 is also coupled to non-volatile storage 307 , such as a flash memory or other read only memory (ROM) 308 and/or hard disk drive 309 . The computer system 300 may be connected to a communication network 322 , such as the Internet, by the communication device 313 , such as a modem, but the connection may be established by any desired network communication device known to those of skill in the art. Though the processor 302 is shown as being coupled directly to a display device 314 , the processor may also be coupled indirectly to the display 314 through a display or I/O controller device. Similarly, the processor is shown as being coupled through the I/O controller 304 to the non-volatile memory 307 , though direct coupling is also contemplated.
[0025] Various programming codes and software are stored in the memory. For example, the basic input/output system (BIOS) code 311 that starts the computer system 300 at startup may be stored in a BIOS ROM device of the non-volatile storage 307 , such as a ROM (Read Only Memory) or a PROM (Programmable ROM) such as an EPROM (Erasable PROM), an EEPROM (Electrically Erasable PROM), a flash RAM (Random Access Memory) or any other type of memory appropriate for storing BIOS. The BIOS 311 is essentially invisible to the user and boots to the operating system.
[0026] Software 330 includes an operating system 330 and a performance monitoring module 332 .
[0027] Referring to FIG. 4 , a block diagram of the processor 302 is shown. In one embodiment, the processor 302 is a processor available from Advanced Micro Devices. The processor 302 includes a processor core 410 , a bus or interface unit 412 , a graphics processor 414 , a display controller 416 , and a video processor 418 . The processor 202 also includes a memory controller 430 , an I/O controller interface 432 , a display device interface 434 and a configurable performance module 440 , though it will be appreciated that these controllers and interfaces may be implemented externally to the processor 302 . The processor 302 executes software stored in the memory 206 , 207 .
[0028] The configurable performance module 440 enables the processor 302 to have an initial performance level set during the fabrication of the processor 302 , but then to have the performance level of the processor be reconfigurable after point of sale of the processor 302 .
[0029] FIG. 5 shows a block diagram of the configurable performance module 440 . More specifically, the configurable performance module 440 includes a performance control circuit 510 a performance lock circuit 512 and a security circuit 514 . The performance control circuit 510 is coupled to the performance lock circuit 512 . The performance control circuit 510 receives a first clock signal (clock A) and provides a second clock signal (clock B). The performance lock circuit 512 is coupled to the security circuit 514 and the performance control circuit 512 . The performance lock circuit 512 receives a performance indication. The security circuit 514 receives an authorization signal. The security circuit 514 is coupled to an integrated circuit unique identifier as well as the performance lock circuit 512 .
[0030] The performance lock circuit 512 causes the performance control circuit 510 to function at a certain predefined performance level until and unless certain conditions are met to enable the performance of the processor 510 to be changed (e.g., increased). The security circuit 514 ensures that any change in performance indication is appropriately authorized. For example, for performance of the processor to be increased, a predefined performance indication is received along with a predefined authorization. The performance lock circuit 512 may be further configured such that the performance indication and the authorization must be received within a predefined time window. Also for example, the authorization might be encrypted such that some form of unique identifier is used to decrypt the authorization. This unique identifier might be a serial number or some form of lot identifier such that this information is not readily discoverable, but also does not disclose or provide any customer confidential information.
[0031] FIG. 6 shows a block diagram of the operation of the integrated circuit performance monitor module 332 . More specifically, the integrated circuit performance monitor module 332 starts operation by monitoring the performance of the integrated circuit to which it is assigned at step 610 . The integrated circuit performance monitor module 332 determines whether a performance threshold has been exceeded at step 612 . The performance threshold may be a one time exception (e.g., a certain percentage of performance availability is exceeded), an ongoing exception (e.g., a certain percentage of performance availability is exceeded for a certain amount of time or is exceeded a certain percentage of time) or some combination of a one time type exception and ongoing exception.
[0032] If no threshold has been exceeded, then the integrated circuit performance monitor module 332 continues to monitor performance at step 610 .
[0033] If a performance threshold is exceeded then the integrated circuit performance monitor module 332 presents a performance increase offer to the user of the computer system at step 620 . The performance increase offer may be a one time increase offer (e.g., by the customer paying a certain amount, the increased performance is unlocked), may be an ongoing increase offer (e.g., the customer may pay an ongoing regular amount to have the performance unlocked while the customer is paying, e.g. a lease for the increased performance), the performance increase offer may be a selective increase offer for the times when the increased performance is needed (e.g., the performance control circuit 512 is unlocked in such a way that when the customer needs increase performance, that performance is provided and then the customer only pays for the times when the increased performance is used.)
[0034] If the offer is not accepted as determined at step 622 , then the performance threshold is reset at step 622 and the integrated circuit performance monitor module 332 continues to monitor performance at step 610 . The user can also optionally indicate a desire to no longer monitor performance when the offer is declined.
[0035] If the offer is accepted as determined at step 622 , then the integrated circuit performance monitor module 332 initiates a process for obtaining consideration for increasing the performance of the integrated circuit at step 630 .
[0036] Once consideration has been obtained, then the performance increase operation is performed at step 632 . Based upon the customer decision and consideration, the performance increase may be to the maximum possible performance increase available to the integrated circuit or some portion less than the maximum possible performance increase. If there is additional available performance increase possible as determined at step 640 , then the threshold is reset at step 624 and the integrated circuit performance monitor module 332 continues to monitor performance at step 610 . If there is no remaining performance increase available, then the operation of the integrated circuit performance monitor module 332 completes.
[0037] The present invention is well adapted to attain the advantages mentioned as well as others inherent therein. While the present invention has been depicted, described, and is defined by reference to particular embodiments of the invention, such references do not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts. The depicted and described embodiments are examples only, and are not exhaustive of the scope of the invention.
[0038] For example, the above-discussed embodiments include modules that perform certain tasks. The modules discussed herein may include script, batch, or other executable files. The modules may be stored on a machine-readable or computer-readable storage medium such as a disk drive. Storage devices used for storing software modules in accordance with an embodiment of the invention may be magnetic floppy disks, hard disks, or optical discs such as CD-ROMs or CD-Rs, for example. A storage device used for storing firmware or hardware modules in accordance with an embodiment of the invention may also include a semiconductor-based memory, which may be permanently, removably or remotely coupled to a microprocessor/memory system. Thus, the modules may be stored within a computer system memory to configure the computer system to perform the functions of the module. Other new and various types of computer-readable storage media may be used to store the modules discussed herein. Additionally, those skilled in the art will recognize that the separation of functionality into modules is for illustrative purposes. Alternative embodiments may merge the functionality of multiple modules into a single module or may impose an alternate decomposition of functionality of modules. For example, a software module for calling sub-modules may be decomposed so that each sub-module performs its function and passes control directly to another sub-module.
[0039] Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects.
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A method for manufacturing an integrated circuit. The method includes fabricating the integrated circuit, the integrated circuit being fabricated to operate at a first performance level; sorting the integrated circuit to a second performance level; locking the integrated circuit to operate at the second performance level when manufacturing the integrated circuit, the integrated circuit being configured to be unlocked to operate at the first performance level.
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PRIOR APPLICATION
This is a US national phase application that claims priority from Swedish patent application no. SE 1451445-9, filed 27 Nov. 2014.
FIELD OF THE INVENTION
The present invention relates to a method for producing pulp. More particularly, it concerns a displacement batch cooking process comprising a displacement phase using a temperature gradient in the displacement liquor used.
BACKGROUND OF THE INVENTION
The prehydrolysis-sulfate (Kraft) cooking for the production of special pulps having a high content of alpha cellulose was developed in the 1930's, see e.g. Rydholm, S. E., Pulping Processes, pp. 649 to 672, Interscience Publishers, New York, 1968. The basic idea is to remove as much hemicellulose as possible from cellulose fibers in connection with delignification, so as to obtain a high content of alpha cellulose. This is essential because the various end uses of such pulps, dissolving pulp for instance, do not tolerate short-chained hemicellulose molecules with a randomly grafted molecular structure.
A separate prehydrolysis step permits the desired adjustment of the hydrolysis of hemicelluloses by varying the hydrolysis conditions. In the prehydrolysis-kraft cooking process the necessary delignification is not carried out until a separate second cooking step. The prehydrolysis is carried out either as a steam or water phase prehydrolysis, or in the presence of a catalyst. In the former “steam” processes, organic acids liberated from wood during the process establish the necessary pH conditions and perform a major part of the hydrolysis, whereas in the latter “water” process, small amounts of mineral acid or sulfur dioxide may be added to “assist” the prehydrolysis. In the prehydrolysis stage carried out in a steam phase, often called autohydrolysis, direct steam is introduced to the chip column in the digester. Conventionally, autohydrolysis is established at some 30-40° C. higher temperature than in liquid filled hydrolysis.
Conventionally after prehydrolyzing the cellulosic material in a reactor, the hydrolysate and the prehydrolyzed cellulosic material are neutralized in the reactor with alkaline neutralizing liquor so as to produce neutralized hydrolysate and neutralized prehydrolyzed cellulosic material. There is hydrolysate both in the free liquid outside the chips and also trapped and immobilized inside the chips. In Bio Pulping, as much as possible of the hydrolysate can be recovered before the neutralization step in order to be able to utilize the carbohydrates released in the prehydrolysis as an additional product from the mill. A separate washing stage, in which the digester is first filled up with a washing liquid and then the liquid containing the carbohydrates is removed from the digester, can be used between the prehydrolysis and cooking stages. Conventionally, both the liquid filling of the digester as well as removal of the dissolved carbohydrates are done by a displacement process using heated wash liquors, all in order to maintain the temperature of the cellulose material.
EP 2430233 discloses another method to recover the hydrolysate from a steam phase prehydrolysis. In EP 2430233 hot water is introduced into the digester after prehydrolysis at top and bottom and subjected to internal circulation while filling the digester. The water filling may be continued until the entire chip volume inside digester is drenched in water. The hot water is heated to the intended temperature and stored in hot water accumulator before usage. The heating is done up to a temperature close to the temperature of the hydrolysis.
Also, a sequence of multiple displacement liquors may be used in a sequence during displacement, and one such sequence is shown in EP796367. After a prehydrolysis at some 170° C. is the hydrolysate neutralized by displacing a hot white liquor pad through the digester at some 155° C., and thereafter is kraft cooking commenced using spent cooking liquor at some 148° C. in a first phase. A problem here is that the very first portion of the hot white liquor pad that meets the hot acidic chips both is heated by the chips and due to exothermic reactions further elevate the temperature in the white liquor pad, and this while the alkali content is consumed. Thus, the last upper volume of the digester content will be exposed to a hot and alkali depleted white liquor pad that is not able to end the prehydrolysis. This will cause an extended prehydrolysis in upper part of digester in comparison to lower part, and the difference in prehydrolysis effect between upper and lower part of digester could be some 17-150%.
Similar displacement using a white liquor pad, added in volume at some 30 m 3 in a digester with a total volume about 300 m 3 , is also disclosed in EP2567023, but ahead of a CCE-filtrate added in volume at some 130 m 3 . Sequential displacement from bottom is also disclosed for hot black liquor filling as well as final liquor displacement. All displacement liquors used having an isothermal temperature when adding them to the digester.
While the processes hereto has been optimized for maintaining the established heat value in the digester, i.e. avoiding losses of heat value in the process, most implementations has used excessive heating of process liquors added after a hot treatment stage. The objective in this excessive heating has been to maintain the temperature of the content of the digester high, avoiding the losses that may be at hand if the digester is first elevated to a high process temperature, then lowered in temperature, followed by heating again to establish a higher temperature. Each such swing in temperature leads to heat losses per default, even if heat recovery is implemented after each phase.
The system has thus been designed with large accumulators for storing the heated process liquors, which accumulators are equipped with circulation systems and heat exchangers in order to heat the liquors to this elevated temperature before use at the specific treatment phase.
What is also seen in the prior art is that even if these high temperature liquors are used to end a treatment phase, the digester content is subjected to different H-factor exposure as of content close to bottom VS content close to top, and especially if the temperatures differ between phases. Using an isothermal displacement liquor after a hot treatment phase, and a somewhat colder displacement liquor to the bottom of the digester, will impose a larger cooling effect on the digester material contained in the bottom VS the digester material contained in the upper part. This due to that the displacement liquor will be heated by the digester material during displacement and in some cases due to exothermic reactions. At the instant where the displacement front reach the top is the temperature of the free displacement liquor often more than 20-40° C. higher than the temperature of the displacement liquor last added to the bottom. Now, the temperature profile may be even out afterwards by circulation, but the harm has already been done at the moment this temperature profile is obtained.
OBJECT OF THE INVENTION
The object of the present invention is to improve a displacement following a general heated treatment stage which will result in better uniformity in the pulp produced. It is especially the uniformity of pulp, as seen in over the extension of the digester between top and bottom that is improved as the P- or H-factor will be more similar over the entire content of the digester.
H-factor is a kinetic model for the rate of delignification in kraft pulping. It is a single variable model combining temperature (T) and time (t) and assuming that the delignification is one single reaction (see Herbert Sixta, Handbook of Pulp, Volume 1, Wiley-VCH Verlag 2006, pages 343-345), and P-factor is the equivalent factor for hydrolysis processes also taking the temperature and time into account.
For H-factor the delignification process doubles the reaction rate for each 8-10° C. increase starting from a temperature of about 90-100° C. where the delignification rate is almost 0 at all practical retention times and at single H-factor digits even at a retention time of 400 minutes at 100° C.
For the hydrolysis process the P-factor during 10 minutes is about 100 units at 170° C., only 20 units at 150° C. and practically neglect able at 130° C. Hence, for controlling the appropriate ending of a prehydrolysis sufficient low temperature should be established.
For ending a prehydrolysis stage it is necessary to change the conditions favoring the prehydrolysis reactions, i.e. a low pH and high temperature. In the prior art has hot white liquor been charged that at end of displacement may be heated to full prehydrolysis temperature or even higher, and this requires excessive charges of white liquor. With the invention the alkali charge may be reduced as an effective lowering of the temperature is established.
As process liquors may be used at start of displacement, not requiring heating before use, could saving in heating (less use of steam) be obtained in first phases. The necessary heating accumulators may also be smaller (less investment) as the necessary volumes of heated liquors decrease.
The present invention may be applied after any kind of heated treatment phase, where the treatment result on the material content in the digester is a result of exposure of time and temperature, i.e. H-factor or P-factor.
The present invention may preferably be applied after hydrolysis, both after steam hydrolysis, as well as liquid filled hydrolysis. The present invention is preferably applied in a prehydrolysis kraft process, where first prehydrolysis is performed at high temperatures in the order of 170° C., while subsequent black liquor impregnation is implemented at quite lower temperature below 155° C., even as low as down to 100° C., which impregnation is followed by cooking at some 135-170° C.
However, any displacement phase after impregnation or cooking liquor establishment as well as final wash may benefit from the invention, as more total equal H-factor may be obtained for the entire digester content. Equal impregnation effect is also a necessity ahead of cooking in order to obtain same pulp quality of the digester content.
SUMMARY OF THE INVENTION
The present invention is related to a method for ending a heated treatment phase in a displacement batch pulping process in a digester vessel, where the treatment phase has been done at a treatment temperature above 130° C., preferably above 150° C. The digester has at least a bottom, a mid-point and a top liquid exchange position. The method is initiated after the heated treatment phase and has the following steps;
adding a first displacement liquor to the bottom liquid exchange position while having a first lower temperature more than 20° C. below the treatment temperature in the first displacement liquor at start of the displacement filling a part of the digester with a first volume of an first displacement liquor, continuing to add the same first displacement liquor to the bottom liquid exchange position while having a higher second temperature in the first displacement liquor in a later phase of the displacement filling at least a part of the digester with a total second volume of the first displacement liquor larger than the first volume, and optionally continuing the displacement with a final displacement liquor.
By this principle could the temperature profiling of the displacement liquor reduce the residual H-factor exposure on the digester content of cellulosic material from the preceding heat treatment, obtaining less difference in pulp quality between the pulp blown first and last from digester. The final displacement liquor may be a different liquor than that used for the initial displacement liquor, but they may also be the same.
A typical state of the art batch digester with a digester volume in excess of 300 m 3 , may require some 20-30 minutes for a full displacement cycle. Hence, the P- or H-factor exposure on the digester content may differ quite a lot for the digester content, as the bottom content is effectively ending the heat treatment sooner than is obtained in the top content of the digester. Thus using a colder liquor in the first part of displacement will prevent this liquor from reaching excessive temperature at end of displacement.
According to a preferred embodiment the displacement process is improved such that the final displacement liquor is supplied and displaced until the content of the digester vessel is completely submerged under the total volume of the final displacement liquor added and wherein the first displacement liquor has been displaced from the digester via the top liquid exchange position. In this embodiment the first displacement liquor may be used entirely as a neutralization liquor with the sole objective to swing the digester content towards alkaline conditions during alkali consumption that may consume most of the alkali content.
According to yet a preferred embodiment the displacement process is improved such that after adding the first displacement liquor with the higher second temperature and before the content of the digester vessel is completely submerged is the displacement continuing by adding the same first displacement liquor to the bottom liquid exchange position while having a third temperature higher than the second temperature in the displacement liquor in a later phase of the displacement filling a part of the digester with a total third volume of first displacement liquor larger than the total second volume. In some applications more than 2 stages in the temperature profiling may be beneficial, depending on size of digester and the necessary time for starting and ending the displacement, which may take up to 10-20 minutes or more.
This may also be further improved by that the temperature in the first displacement liquor increase is done in incremental steps in at least 3 and up to 10 steps during the displacement. Alternatively, the temperature increase in the first displacement liquor may be done continuously during the displacement.
In a preferred embodiment the displacement may be succeeded with initiation of a circulation of the liquor is after the digester vessel has been filled by the final displacement liquor. This may improve further equalization of residual heat in the digester content.
In a preferred embodiment of the inventive method that is especially advantageous when using a white liquor pad as neutralization liquor after a prehydrolysis and using only 2 temperatures in a first cold and a second hot white liquor pad is the proportion of the first volume of the first displacement liquor in relation to the total volume of the first displacement liquor in the range 20-50%. This part volume of the total white liquor pad establish a sufficient part volume that could absorb most if not all of the exothermic heat release during displacement, but also most of the residual heat value of the digester content.
Also preferable when implementing the inventive method after prehydrolysis is that the total volume of the first displacement liquor is in the range 50-75% of the free digester volume, i.e. not filling the entire digester with this neutralization liquor which may reduce total alkali consumption.
In order to absorb most of the exothermic heat release and the residual heat in the digester content but still not reaching high temperatures close to those high temperatures supporting hydrolysis reactions, is preferably the first lower temperature in the first displacement liquor in the range 70-110° C., preferably 90-100° C.
As indicated before, the inventive method is preferably applied after prehydrolysis wherein the heated treatment phase is a prehydrolysis phase wherein the digester content is hydrolyzed at a temperature above 150° C. In such high temperature hydrolysis process is the residual heat value in the digester content quite high and even further heated by reaction heat formed in neutralization, so a hydrolysis effect is maintained to a large extent in final digester content volumes displaced by the displacement liquor, while first digester content volumes displaced are sooner to lower the temperature and end the hydrolysis, whereby a forced temperature profiling may reduce difference in P-factor exposure. Typically the reaction heat formation in neutralization is estimated to 0.1-0.2 GJ/tBD wood resulting in up to 10° C. temperature increase in on average for the liquor filled digester.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a schematic layout of a batch digester system with the components necessary to implement the invention in a white liquor displacement phase;
FIG. 2 a is showing the a principle effect from exothermic reaction during a conventional displacement front through the digester using a hot white liquor pad WLP at a temperature of 150° C. displaced trough the digester;
FIG. 2 b is showing a conventional circulation phase after FIG. 2 a in order to establish same temperature throughout the digester after the displacement;
FIG. 3 a is showing a principle effect heating from digester content during a conventional displacement front through the digester using a first white liquor pad WLP at a temperature of 150° C. displaced by hot black liquor at a temperature of 130° C.;
FIG. 3 b is showing a conventional circulation phase after FIG. 3 a in order to establish same temperature throughout the digester after the displacement;
FIG. 4 is showing the principle effect of the inventive displacement front through the digester using a hot white liquor pad at successively higher temperature charged at 90° C. in first phase and up to 150° C. in a second phase;
FIG. 5 a is showing the principle effect of the inventive displacement front through the digester using a displacement liquor at successively higher temperature in 7 stages during complete filling of the digester; and
FIG. 5 b is showing an optional circulation phase that may be implemented after FIG. 4 a in order to absorb some of heat value still contained in the digester content.
DETAILED DESCRIPTION OF THE INVENTION
The description will be made using the schematic layout shown in FIG. 1 which only discloses the essential components for the system used necessary to implement the present invention in a white liquor displacement phase. In a full commercial plant is also additional equipment added for performing the kraft cook and heat recovery after cook, for example using warm and hot black liquor accumulators.
Only one digester is shown but typically a number of digesters are used that operate in sequence and thus in different phases of the cook. If for example 5 digesters are operated the first digester is started and then the remaining digesters are started at some time interval which time interval may correspond to ⅕ of the total cooking cycle time for one digester. Cooked pulp may then be blow to a blow tank at regular intervals, and the process liquids stored in accumulators and atmospheric tanks may be used in another digester minimizing inactive dwell time for the liquids used. The piping system is simplified showing only one liquid addition point for WL, Wash filtrate, LP_ and MP-steam but in a real system are individual piping connected to the inlet point of the digester.
During the white liquor displacement phase is white liquor used that typically is obtained from the caustization. This white liquor conventionally has a temperature of about 90° C. as it has been stored in atmospheric tanks. The white liquor is heated before supply to the hot white liquor accumulator in at least one heat exchanger HE 2P , using hotter process liquors or steam as heating medium. The content of the hot white liquor accumulator is also heated in a circulation containing an additional heat exchanger HE 2C , using hotter process liquors or steam as heating medium. The heating is performed until the entire accumulator content has reached the intended temperature which in the figure may lie at some 150° C. lif the total digester volume is about 300 m 3 , the total free volume inside a digester filled with comminuted chips is about 200 m 3 , so the accumulator needs a size of 200 m 3 to store this volume for a full displacement phase.
In FIG. 2 a is shown the principle heating effect from exothermic reactions during a conventional displacement front through the digester using a hot white liquor pad at a temperature of 150° C. In this example a drained digester is shown with a digester content of comminuted chips after a heated treatment in form of a prehydrolysis conducted at 170° C. In a first stage, first left hand figure, of the displacement phase is the inlet cone part filled with a volume of white liquor holding 150° C. when added. In a second stage, second figure from left, of the displacement phase is the inlet cone part filled with a volume of hot black liquor holding 130° C. when added, pushing the hot white liquor pad WLP upwardly. During this displacement will exothermic heat be released as alkali is consumed when the upper level of the white liquor pad neutralizes the acidic digester content but now heated to a higher temperature due to exothermic reactions. The heating effect due to exothermic reactions is in the range 0.138-0.206 GJ/odt of wood.
This continues in stages until the entire digester is filled with displacement liquor, and as a result of the heating from the exothermic reaction is a temperature profile established over the height of the digester, with a temperature of the free liquor close to the hydrolysis temperature, i.e. close to 170° C. in top but close to 130° C. in bottom. Now, the digester content in bottom has been flushed by 130° C. wash liquor during the entire displacement and is very close to 130° C. But the digester content in top has only been drenched by heated white liquor with most of the alkali content consumed during neutralization. As a result the hydrolysis is ended much sooner in bottom of digester, as the temperature has been lowered to 130° C. at an early stage and alkali has been present, while the digester content in the top is subjected to extended hydrolysis, as the criteria's for ending the hydrolysis, lowering of temperature and change to alkaline conditions has not been fulfilled.
This temperature profile may be even out by a circulation as shown in FIG. 2 b , which starts from a condition corresponding to the rightmost hand figure in FIG. 2 a , where a pump starts to withdraw liquor from mid-point liquid exchange position and return this liquor to both top and bottom. This will result in some heating in bottom and cooling in top and ideally the entire content of the digester assumes a temperature lying in-between the hot black liquor temperature and the hydrolysis temperature at end of circulation, as disclosed in the right hand figure.
In FIG. 3 a is shown the additional principle heating effect from the residual heat content of the digester during a conventional displacement front through the digester using a hot white liquor pad at a temperature of 150° C. In this example is a drained digester shown with a digester content of comminuted chips after a heated treatment in form of a prehydrolysis conducted at 170° C. In a first stage, first left hand figure, of the displacement phase is the inlet cone part filled with a volume of hot white liquor holding 150° C. when added. In a second stage, second figure from left, of the displacement phase is the inlet cone part filled with a volume of hot black liquor holding 130° C. when added, pushing the first volume upwardly but now heated to a higher temperature by the digester content. This continues in stages until the entire digester is filled with displacement liquor, and as a result of the heating from the digester content is a temperature profile established over the height of the digester, with a temperature of the free liquor elevated some 10° C. in top but close to 130° C. in bottom. Now, the digester content in bottom has been flushed by 130° C. hot black liquor during the entire displacement and is very close to 130° C. But the digester content in top has only been drenched for a short time by heated white liquor that now holds a temperature of about 150+10° C., and has thus most of the heat value from hydrolysis left also in the digester content.
This temperature profile may be even out by a circulation as shown in FIG. 3 b , which starts from a condition corresponding to the rightmost hand figure in FIG. 3 a , where a pump starts to withdraw liquor from mid-point liquid exchange position and return this liquor to both top and bottom. This will result in some heating in bottom and cooling in top and ideally the entire content of the digester assumes a temperature lying in-between the hot black liquor temperature, about 130° C., and the added heating from the digester material release, about 140° C., at end of circulation, as disclosed in the right hand figure.
These two examples in FIGS. 3 a and 4 a show the two independent heating effects from exothermic reactions and heating from digester material respectively, and that the usage of an isothermal displacement liquor results in a temperature profile in the digester, and hence is the digester content in top and bottom of digester subjected to quite a difference in H- or P-factor exposure resulting a variance in the pulp quality.
According to the invention a deliberate temperature profiling is instead implemented in the displacement liquor used, either as a part of a displacement pad or throughout a complete filling of the digester.
Embodiment in White Liquor Pad
In FIG. 4 is a first embodiment of the inventive displacement through the digester shown using displacement liquor, i.e. the one and same displacement liquor as of chemical content, which in at least 2 incremental steps, at temperatures of 90° C. and finally 150° C. is used. In this example a drained digester is shown with a digester content of comminuted chips after a heated treatment in form of a prehydrolysis conducted at 170° C. In a first stage, first left hand figure, of the displacement phase is the inlet cone part filled with a first volume of white liquor holding 90° C. when added. In a second stage, second figure from left, of the displacement phase is the inlet cone part filled with a second volume of hot white liquor holding 150° C. when added, pushing the first volume upwardly. The first and second volumes establish a white liquor pad (WLP) that is thereafter displaced trough the digester content by adding hot black liquor holding a temperature of about 150° C. With this temperature profiling of the white liquor, using an unheated white liquor in first phase, will this low temperature part of the WLP absorb the exothermic heat release as well has residual heat in the digester content, avoiding the temperature to become excessive. As indicated an upper layer of the first volume will be heated during displacement and this heated layer HL will increase during the displacement. Due to the initial low temperature at some 90° C., the heating from both exothermic reactions and residual heat in digester content will not be able to raise the temperature close to full hydrolysis temperature which will guarantee that the hydrolysis will be ended. This even if the alkali content has been depleted by the consumption during neutralization. The total volume of the White Liquor Pad WLP is 50-70% of the free volume inside digester and the first colder volume of the WLP is 20-50% of the WLP.
Embodiment in Digester Filling Phase
In FIG. 5 a is an alternative embodiment of the invention shown during a complete filling of the digester with one and the same liquor, but with a forced temperature profile. This temperature profiling may be implemented after the White Liquor Pad displacement as shown in FIG. 4 .
The principle effect of the inventive displacement front through the digester shown using a displacement liquor, i.e. the one and same displacement liquor as of chemical content, that in at least 2 or 3 incremental steps, which in FIG. 5 a are 7 incremental steps, at temperatures of 90-92.5-95-97.5-100-102.5 and finally 105° C. is used. In this example a drained digester is shown with a digester content of comminuted chips after a heated treatment in form of a prehydrolysis conducted at 170° C. In a first stage, first left hand figure, of the displacement phase is the inlet cone part filled with a volume of wash liquid holding 90° C. when added. In a second stage, second figure from left, of the displacement phase is the inlet cone part filled with a volume of wash liquid holding 92.5° C. when added, pushing the first volume upwardly but now heated to a higher temperature by the digester content to about 92.5° C. This continues in stages until the entire digester is filled with displacement liquor, and as a result of the heating from the digester content is an ISO temperature profile established over the height of the digester, with a temperature of the free liquor close to about 105° C. in the entire digester. The total heating effect is about 10° C. from exothermic reactions and about 10° C. from heat value in digester content. Now, the digester content in bottom has been flushed by liquor during the entire displacement and most of the heat value in the digester content has been absorbed in the liquor, while the digester content in top has only been drenched by heated liquor and has thus most of the heat value from hydrolysis left in the digester content.
This temperature profile may be even out by a circulation as shown in FIG. 5 b , which starts from a condition corresponding to the rightmost hand figure in FIG. 4 a , with an isothermal temperature profile of the free liquor, where a pump starts to withdraw liquor from mid-point liquid exchange position and return this liquor to both top and bottom. This will result in some heating of the free liquor by the excess residual heat in the digester content in top throughout the digester. Ideally, the entire content of the digester, both the chips and the free liquor, assumes a temperature lying somewhat above the temperature of the free liquor at end of displacement, as disclosed in the right hand figure.
Alternative Embodiments
Alternatively, the forced temperature profiling of the displacement liquor may even be modified so that the temperature of the free liquor in the final phase of displacement is not isothermal throughout the digester, but could still have a slight temperature profile with either colder or warmer temperature in final 7 th displacement phase. Hence, the digester content in bottom that is displaced by largest amount of displacement liquor may have the lowest residual heat value in the digester content, and therefore could the temperature increase be larger in the steps disclosed in FIG. 5 a.
As the objective is to expose the digester content of iso-H factor exposure, could the forced temperature profiling be controlled exponentially so that the digester content may be exposed to less total cooling effect in latter stages of displacement, i.e. using less temperature increase in first 1-3 phases and then successively higher temperature increases in last 4-7 phases.
The effect of the temperature profiling could be controlled in the pulp finally blown from the digester, taking a sample of the first blow pulp and then a sample from the last blown pulp from the digester and compare pulp quality between these samples as of viscosity, tear strength or other pulp characteristics that may be effected by the specific displacement process.
If the inventive displacement process is implemented after a prehydrolysis, could for example differences in first and last blow pulp be compared as to residual content of hemicellulose that is supposed to dissolve during the prehydrolysis. If the first blown pulp, i.e. the digester content in bottom during treatment, has a higher content of hemicellulose, one may assume that the hydrolysis has not been obtained to the same extent as the last blown pulp thus suggesting an alteration of the temperature profiling towards a higher temperature in the lower part during the displacement phase.
The temperature profiling during the displacement could easily be implemented in a principal system as that disclosed in FIG. 1 by using only unheated liquor (90° C.) in first phase, i.e. opening valve V 2A while having valve V 2B closed. Then as disclosed in figures could a change be implemented in several stages, gradually opening the valve V 2B in steps as functionally disclosed in figures, or alternatively opening the valve gradually over the entire control process. The total volume of the liquor accumulator could thus be reduced considerably, as the total heated liquor volume is reduced in proportion to usage. The opening of the valve V 2B may be controlled by a temperature sensor located after mixing of the unheated and heated wash liquors, as disclosed in FIG. 1 .
While the temperature profiling has been disclosed after a prehydrolysis, the very same temperature profiling may be forced to any displacement liquor added to batch digester to end a preceding heated phase where temperature and time exposure on the digester content of cellulosic material play a role in that treatment phase. Thus, the Hot White Liquor accumulator shown in FIG. 1 may alternatively be a Wash Liquor or Hot Black Liquor accumulator.
While the present invention has been described in accordance with preferred compositions and embodiments, it is to be understood that certain substitutions and alterations may be made thereto without departing from the spirit and scope of the following claims.
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The method is for producing pulp in batch digesters. More particularly, the method is for ending a treatment phase of the digester content. In order to obtain a more uniform pulp quality from the process is the treatment phase ended by displacing a liquor volume (WLP) through the digester vessel with an imposed increasing temperature in the displacement liquor added to digester.
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BACKGROUND OF THE INVENTION
1. Description of the Prior Art:
Prior art high voltage generating circuits of television receivers have hitherto comprised so-called pulse rectifying systems in which the resonant frequency in a flyback transformer is selected to be higher than the horizontal sweep frequency of 15.75 KHz, that is, for example, about 50 KHz. This flyback transformer generates a high voltage narrow width pulse of horizontal period which is peak-value-rectified by a rectifier circuit consisting of a diode. Such prior art pulse rectifying systems have the drawback that when the high voltage load current increases, the high voltage is greatly lowered since the angle of current flow of the diode in the rectifier circuit is quite small and the regulation is inferior.
Further, there has been considered such a system that the high voltage pulse is converted into a sine-wave voltage by using a resonant circuit which is tuned to the vicinity of the horizontal frequency, and this sine-wave voltage is rectified by a rectifier circuit consisting of a diode to obtain the high voltage. According to the sine-wave rectifying system, the angle of current flow of the diode in the rectifier circuit becomes wider than that of the pulse rectifying system and the regulation of the high voltage is slightly improved. However, even in the sine-wave rectifying system, there is the fear that when the high voltage load current is changed, the resonant frequency of the resonant circuit will also be changed, and hence the high voltage will be varied.
The present device comprises a high voltage generating circuit as shown in FIG. 1, in which the high voltage will not be varied even when the load is varied.
2. Field of the Invention:
The field of art to which this invention pertains is high voltage generating circuits for the anode of color television receivers and in particular to circuits designed to improve voltage regulation.
SUMMARY OF THE INVENTION
It is an important feature of the present invention to provide an improved high voltage regulation circuit for a color television receiver.
It is a principal object of the present invention to provide a high voltage regulating circuit for a television receiver which prevents the development or undesirable voltages due to a shift in the horizontal oscillator frequency or at the same time maintain good voltage regulation under high anode current loads.
It is a specific object of the present invention to provide a high voltage regulating circuit which utilizes a flyback transformer having an input resonant frequency in the vicinity of but substantially higher than a horizontal oscillator frequency and wherein the primary winding of the flyback transformer has a series resonant circuit with a resonant frequency in the vicinity of but lower than the frequency of the horizontal oscillator.
It is a further object of the present invention to provide a high voltage regulating circuit as described above wherein the resonant frequency of the flyback transformer is in the vicinity of 20 KHz and wherein the resonant frequency of the series resonant circuit associated with the primary winding of the flyback transformer is in the vicinity of 10 KHz.
These and other objects, features and advantages of the present invention will be understood in greater detail from the following description and associated drawings wherein reference numerals are utilized to designate a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of voltage regulating circuit which produces good voltage regulation upon high anode current load but which can produce undesirable high voltages upon a shift occurring in the horizontal oscillator frequency.
FIG. 2 shows a graphic illustration of the windings of a flyback transformer according to the present invention and in particular shows the arrangement for producing loose coupling between the primary and secondary winding and tight coupling between the secondary and tertiary windings.
FIG. 3 is a frequency-voltage graph illustrating the operation of the circuit of FIG. 1.
FIG. 4 shows two waveforms associated with the operation of the circuit of FIG. 1.
FIG. 5 is a schematic of a high voltage regulating circuit according to the present invention which utilizes a series resonant circuit to prevent undesirable rises in high voltage upon a shift in the horizontal oscillator frequency.
FIG. 6 is a voltage-frequency graph showing the locations of the resonant frequencies developed in the circuit of FIG. 5 and also showing a composite frequency-voltage graph of that circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present device relates to a high voltage generating circuit for use in a television receiver and the like, and particularly a device for improving high voltage regulation and preventing the generation of abnormal high voltages caused by a shift of the oscillating frequency of a horizontal oscillator.
In FIG. 1, reference numeral 1 designates a horizontal oscillator having a frequency of, for example 15.75 KHz. The output side of this horizontal oscillating circuit 1 is connected through a driving circuit 1a to the base electrode of an npn-type transistor 2 forming a switching element, and the emitter electrode of the transistor 2 is grounded. The collector electrode of the transistor 2 is grounded through a damper diode 3 and also grounded through a resonant capacitor 4. Further, the collector electrode of the transistor 2 is grounded through a series circuit consisting of a horizontal deflection coil 5 and a DC block capacitor 6 and also connected through a primary winding 7a of a flyback transformer 7 to a power supply terminal 8 to which a positive DC voltage is supplied. In this case, the primary side of the flyback transformer 7 is selected to have a resonant frequency relatively higher than the horizontal frequency of 15.75 KHz, that is, for example, about 50 KHz so that a pulse having a width corresponding to the horizontal blanking period in a video signal may be generated and also a saw-tooth current of normal horizontal period may flow through the horizontal deflection coil 5. The resonant frequency of the primary side of the flyback transformer 7 is mainly determined by the inductances of the horizontal deflection coil 5 and the primary winding 7a, respectively, and the capacitance of capacitor 4. Since the impedance of the DC block capacitor 6 relative to the horizontal frequency is nearly zero, the effect of the capacitor 6 can be neglected. One end of a secondary winding 7b of the flyback transformer 7 is grounded while the other end thereof is connected through a diode 9 forming a high voltage rectifier circuit to a high voltage terminal 10 for supplying a high voltage to the anode of a cathode ray tube. The connection point between the diode 9 and the high voltage terminal 10 is grounded through a capacitor 11. The capacitor 11 is formed by the conductive films which are respectively deposited on the inner and outer walls of the cathode ray tube in accordance with the prior art. In addition, the flyback transformer 7 is provided with a tertiary winding 7c across which a capacitor 12 is connected to form a resonant circuit. In this case, the resonant frequency of this resonant circuit is selected to be in the vicinity of the horizontal frequency f H , for example, 15.75 KHz, and the waveform of the voltage obtained across the secondary winding 7b of the flyback transformer 7 is substantially sinusoidal.
In this case, the flyback transformer 7 is constructed in such a manner that as shown in FIG. 2, two U-shaped cores 13a and 13b are combined to form a square configuration, the primary winding 7a and the secondary winding 7b are respectively wound about the end portions of the U-shaped cores 13a and 13b, which are respectively opposed to each other, with the electromagnetic coupling between the primary and secondary windings 7a and 7b being made relatively loose (0.5 < K < 0.9, where K is coupling coefficient), and the tertiary winding 7c is wound about the same axis as that of the secondary winding 7b with the electromagnetic coupling between the secondary and tertiary windings 7b and 7c being made relatively close (K > 0.9).
In FIG. 1, the inductance values of the primary, secondary and tertiary windings 7a, 7b and 7c of the flyback transformer 7, the inductance value of the horizontal deflection coil 5, the capacitance value of the capacitor 12, and the values of the electromagnetic coupling coefficients K of the primary, secondary and tertiary windings 7a, 7b and 7c of the flyback transformer 7 are respectively selected so that the resonant frequency of the system looking into the flyback transformer 7 from a point A may be a little higher than the horizontal frequency f H or 15.75 KHz, that is, for example, 20 KHz as shown in FIG. 3 by a solid line P.
Since the high voltage generating circuit of FIG. 1 is constructed as described above, a pulse signal or horizontal period H as shown in FIG. 4A is obtained at the primary side of the flyback transformer 7. Further, since the resonant frequency looking into the flyback transformer 7 from the point A is selected to be in the vicinity of the horizontal frequency f H or 15.75 KHz, that is, for example, 20 KHz, the flyback transformer 7 produces across the secondary winding 7b thereof a signal whose waveform is substantially sinusoidal but its peak portion is flattened as shown in FIG. 4B. Accordingly, the angle of current flow of the rectifier 9 is widened, and the regulation of the high voltage derived from the output terminal 10 is improved.
In this case, when a high voltage load current does not flow, the capacitor 11 is electrically charged up to the peak value of the waveform shown in FIG. 4B, and the diode 9 becomes nonconductive. At this time, the capacitor 11 is in such a condition as being electrically disconnected from the flyback transformer 7, and hence the capacitance value of the capacitor 11 may not affect the resonant frequency of the flyback transformer 7. When a high voltage load current flows therethrough, the electric charge stored in the capacitor 11 flows to the cathode ray tube, so that the voltage across the capacitor 11 is decreased. In order to compensate for the above voltage drop, a voltage produced at the secondary winding 7b of the flyback transformer 7 is fed through the diode 9 to the capacitor 11. Thus, when the diode 9 becomes conductive, the capacitor 11 will be connected to the secondary winding 7b of the flyback transformer 7, and the resonant frequency of the flyback transformer system, that is, the central frequency of the resonant frequency characteristic is moved toward the horizontal frequency f H , for example, 15.75 KHz, as shown in FIG. 3 by a dotted line θ, with the result that the output, that is, the voltage produced across the secondary winding 7b will be increased. As a result, it is possible to reduce the lowering of the high voltage caused by increasing the high voltage load current.
As mentioned above, according to the embodiment of FIG. 1, since the resonant frequency of the flyback transformer system looking from the side of the primary winding 7a of the flyback transformer 7 is selected higher than the horizontal frequency, the capacitor 11 of the like comes to be connected to the resonant circuit of the flyback transformer system when the high voltage load current flows therethrough and the resonant frequency is lowered to increase the voltage produced at the secondary winding 7b of the flyback transformer 7. Further, the resonant circuit consisting of the tertiary winding 7c and the capacitor 12 affects the voltage produced at the secondary winding 7b of the flyback transformer 7 to change its waveform to be substantially sinusoidal with its peak portion being flattened as shown in FIG. 4B. As a result, the angle of current flow of the diode 9 forming the high voltage rectifier circuit is widened and the lowering of the high voltage caused by the increase of the high voltage load current can be reduced. Thus, the regulation of the high voltage can be improved.
However, in the high voltage generating circuit as shown in FIG. 1, if the oscillating frequency of the horizontal oscillating circuit 1 is shifted from the normal horizontal frequency 15.75 KHz to, for example, about 20 KHz upon turning on the power supply switch in a television receiver, switching the channel and the like, the high voltage obtained at the high voltage terminal 10 rises above the desired value. This undesirable rise in high voltage is applied to the anode of the cathode ray tube and can produce damage to the cathode ray tube, X-ray radiation and the like.
In view of the above described drawbacks, the present device is to improve the regulation of high voltage similarly as the embodiment of FIG. 1 and also to prevent the generation of undesirable high voltages caused by the shift of the oscillating frequency of the horizontal oscillating circuit.
One embodiment of the high voltage generating circuit of the device will hereinbelow be described with reference to FIG. 5. In FIG. 5, elements corresponding to those in FIG. 1 bear the same reference numerals and detailed description is omitted.
The embodiment of FIG. 5 is different from the embodiment of FIG. 1 in that a capacitor 15 is connected to the primary winding 7a of the flyback transformer 7, and the transistor 2 is fed with a power supply from the power supply terminal 8 through a choke coil 14, but the other portions thereof are formed similarly to those in FIG. 1. Therefore, the resonant frequency characteristics looking into the flyback transformer 7 from the point A will have a first resonant point in the vicinity of 20 KHz as shown by a curve R in FIG. 6, which is similar to the curve P in FIG. 3.
In the embodiment of FIG. 5, the resonant frequency of a series resonant circuit formed by the capacitor 15 and the primary winding 7a of the flyback transformer 7 is selected lower than the horizontal frequency, for example, 9 to 10 KHz. Accordingly, the resonant frequency characteristics of this series resonant circuit is shown in FIG. 6 by a curve S in which a second resonant point is set in the vicinity of 9 to 10 KHz. As a result, the frequency characteristic of the high voltage generating circuit is shown by a curve T in FIG. 6 resulting from the composition of the curves R and S. In this case, a frequency f p1 at the first resonant point is preferably higher than the horizontal frequency f H and lower than twice the horizontal frequency, that is, 2f H . A frequency f p2 at the second resonant point is preferably lower than the horizontal frequency f H and higher than 1/2 the horizontal frequency, that is, 1/2f H . A good example of the high voltage generating circuit according to this device was obtained with the components having the following values: the inductance value of the primary winding 7a of the flyback transformer 7 is 5.4 mH, the inductance value of the tertiary winding 7c thereof is 1.67 mH, the electromagnetic coupling coefficient K between the primary and tertiary windings 7a and 7c is 0.62, the inductance value of the horizontal output transformer 14 is 7.3 mH, the inductance value of the horizontal deflection coil 5 is 950 μH, the capacitance value of the capacitor 4 is 16.0 nF, the capacitance value of the capacitor 12 is 56.0 nF, and the capacitance value of the capacitor 15 is 41.0 nF.
Since the high voltage generating circuit of this device is constructed as mentioned above, the flyback transformer 7 produces across its secondary winding 7b a signal whose waveform is substantially sinusoidal with its peak portion being flattened as shown in FIG. 4B similar to that of the embodiment of FIG. 1, and the angle of current flow of the rectifier circuit composed of the diode 9 becomes widened with the result that the regulation of the high voltage obtained at the high voltage terminal 10 is improved. In this case, as in the embodiment of FIG. 1, when the high voltage load current does not flow, the capacitor 11 is electrically charged up to the peak value of the waveform shown in FIG. 4B. Accordingly, when the capacitor 11 is charged to the voltage of peak value, no current flows through the diode 9 to make it nonconductive. In this case, the capacitor 11 is electrically disconnected from the flyback transformer 7, and hence the capacitance value of the capacitor 11 will not affect the resonant frequency at the side of the flyback transformer 7. Further, when the high voltage load current flows, the electric charge stored in the capacitor 11 flows to the cathode ray tube, so that the voltage across the capacitor 11 is lowered. In order to compensate for this voltage drop, the voltage produced at the secondary winding 7b of the flyback transformer 7 is supplied through the diode 9 to the capacitor 11, so that current flows through the diode 9 to make it conductive.
When the diode 9 becomes conductive, the capacitor 11 is connected to the secondary winding 7b of the flyback transformer 7 and the first resonant frequency f p1 of the flyback transformer system is moved to the lower side. That is to say, the first resonant frequency f p1 is shifted toward the horizontal frequency f H , for example, 15.75 KHz, and the output, that is, the voltage obtained across the secondary winding 7b will be increased. As a result, the lowering of the high voltage caused by increases in high voltage load current can be compensated.
Further, according to this device, with the provision of the series resonant circuit consisting of the capacitor 15 and the primary winding 7a of the flyback transformer 7, the difference between the peak voltage value at the first resonant point, and the voltage value at the horizontal frequency f H becomes small as compared with that of the embodiment of FIG. 1, so that even when the oscillating frequency of the horizontal oscillating circuit is shifted to a higher side upon turning on the power supply switch, switching channels and the like, the high voltage obtained at the high voltage terminal 10 will not become undesirably high.
As described above, according to this device, regulation of the high voltage can be improved similarly to the embodiment of FIG. 1 and also an undesirable high voltage will not be caused by an upward shift of the oscillating frequency of the horizontal oscillating circuit 1.
It will be apparent to those skilled in the art that many modifications and variations may be effected without departing from the spirit and scope of the novel concepts of the present invention.
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A high voltage generating circuit for a television receiver which includes a horizontal oscillator and a switching circuit operating at the horizontal sweep frequency of the television receiver and being coupled to a flyback transformer which has an input resonant frequency in the vicinity of but higher than the horizontal oscillator frequency. The output of the flyback transformer is coupled to a rectifier circuit which in turn is coupled to the high voltage anode of the television receiver. The flyback transformer also has an input resonant circuit which includes a capacitor which is serially connected to the primary winding of the flyback transformer. This series resonant circuit is resonant at a frequency in the vicinity but less than the frequency of the horizontal oscillator with the result that improved voltage regulation is obtained while avoiding excess high voltage which otherwise would be caused by a shift in the output frequency of the horizontal oscillator.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an orally administered antibody with respiratory syncytial virus (RSV), adenovirus, parainfluenza virus, or influenza virus neutralization activity and its use to decrease the incidence or severity of RSV or other viral infections of the upper and lower respiratory tract.
2. Description of the Prior Art
Respiratory syncytial virus is the major cause of pneumonia and bronchiolitis in infancy. Infants between the ages of two and five months have the most severe disease and may require hospitalization. More than half of all infants become infected with RSV during their first year of exposure, and nearly all are infected after a second year. Children who attend day care centers tend to have more severe infections and at an earlier age. Repeated RSV infections are common, although repeat episodes tend to be less severe.
During seasonal epidemics most infants, children, and adults are at risk for infection or reinfection. In addition to infections in healthy infants and children, other groups at risk for serious RSV infections include premature infants, hospitalized children, infants and children with cardiac or pulmonary disorders, immune compromised children and adults, and the elderly. Symptoms of RSV infection range from a mild cold to severe bronchiolitis and pneumonia. Respiratory syncytial virus has also been associated with acute otitis media and RSV can be recovered from middle ear fluid.
Respiratory syncytial virus is an RNA virus that can produce cell fusion (syncytia) in tissue culture. It is classified as a pneumovirus within the paramyxovirus family. The RNA genome codes for at least 10 proteins including two matrix proteins in the viral envelope (Ryan, Sherris' Medical Microbiology, 3d ed., Appleton and Lange, p. 458, 1994). One matrix protein forms the inner lining of the viral envelope. Antigens on the surface of the envelope are the G glycoprotein, the probable attachment site to host cell receptors, and the F glycoprotein that induces fusion. G glycoprotein antibodies can neutralize the virus in vitro.
Infection with the virus causes both IgG and IgA humoral and secretory antibody responses. Immunity is not permanent and repeated infections are common, however the severity of illness tends to diminish with increasing age and with successive reinfection. No vaccine has been shown to be protective against RSV and antiviral drugs have so far had only limited utility. Breast feeding may offer some protection against RSV infection. RSV-specific IgA and IgG antibodies have been found in human milk and colostrum and RSV neutralization can be accomplished in cell culture with both immunoglobulin and non-immunoglobulin components of human milk (Laegreid et al., "Neutralizing Activity in Human Milk Fractions against Respiratory Syncytial Virus, Acta Paediatrica Scandinavica, 75:696-701, 1986).
Okamato et al., (Acta Paediatrica Scandinavica Supplement, 351:137-143, 1989) report that immunity acquired by an infant either through the placenta or through breast feeding may reduce the risk of lower respiratory tract disease. The focus of the report of Okamato et al. is on the role of maternal antibodies transmitted in breast milk and the possible role of breast milk in modulating an infant's immune response to RSV. The focus of the instant invention is on a method of producing passive immunity by adding neutralizing antibodies to a product that will be orally ingested. Orally ingested as used herein refers to a substance that is swallowed by the host.
Previous treatments for infection by RSV have relied upon either parenteral or aerosol administration of agents such as monoclonal antibodies or viricidal drugs such as ribavirin. The present invention discloses oral administration of an antibody with RSV neutralizing activity.
Prince et al. (U.S. Pat. No. 4,800,078) teach a method for topical application of antibodies to RSV into the lower respiratory tract, preferably by administering immunoglobulins as small particle aerosol. The immunoglobulins can also be administered by the intravenous route.
In U.S. Pat. No.5,290,540, Prince et al. disclose topical administration in the form of small particle aerosol of both an anti-inflammatory agent and an anti-infectious agent in the treatment of pneumonia caused by bacteria or viruses including RSV.
CA 2,040,770 to Young et al. discloses a process for the treatment of respiratory viruses, including RSV, by administering a neutralizing or non-neutralizing monoclonal antibody against a fusion protein of RSV (the F glycoprotein). Monoclonal antibody treatment using the method of Young et al. may be topical and administered intranasally or by breathing an aerosol, or systemic by intramuscular administration. The present invention, by contrast, discloses an orally administered treatment.
WO 92/01473 discloses the treatment of lower respiratory tract viral disease using the small particle aerosol method to deliver neutralizing and/or therapeutic monoclonal antibodies to specific viral surface antigenic sites.
WO 92/19244 teaches the combination of an anti-infective agent such as human immunoglobulin G or an antibiotic combined with an anti-inflammatory agent or corticosteroid delivered into the respiratory tract in the form of small particle aerosol.
WO 94/17105 discloses human-murine chimeric antibodies with high specific neutralizing activity against RSV, preferably against the RSV F antigen.
The prior art references disclose delivery of a virus neutralizing compound either topically by inhalation of a small particle aerosol or parenterally by intravenous or intramuscular injection. Feeding a non-absorbed RSV neutralizing compound to prevent or decrease the incidence and severity of RSV infection has not been disclosed or demonstrated in the prior art references. This concept, as demonstrated in the present invention, depends on the ability of an RSV neutralizing antibody to decrease the viral load on mucosal surfaces of the nasopharynx, oropharynx, and hypopharynx, and thereby prevent or decrease the spread of infectious virus from nose to lung when the antibody is swallowed. Delivery of an RSV neutralizing antibody in a liquid product is particularly advantageous because of the ease of administration.
DESCRIPTION OF THE INVENTION
The invention is an orally administered liquid product containing a respiratory virus neutralizing antibody. In one embodiment of the invention the respiratory virus neutralizing antibody is added to a nutritional product. The invention is also a method for delivering an effective concentration of the respiratory virus neutralizing antibody by adding it to a liquid product. As used herein and in the claims a respiratory neutralizing antibody is understood to mean antibody from any mammalian source such as human or bovine that can neutralize respiratory virus. In one embodiment of the invention the respiratory virus neutralizing antibody is added to a nutritional product for infants, such as infant formula, and is fed to the infant during the first year of life. The infant formulation could be a powder for reconstitution with water, a ready-to-feed liquid or a concentrated liquid. Respiratory viruses to which the invention is applicable include respiratory syncytial virus, adenovirus, parainfluenza virus, and influenza virus.
Experimental Protocol
Studies will be undertaken to determine the impact of feeding neutralizing antibodies against human respiratory syncytial virus (HRSV) induced pulmonary infection in animals. Objectives of the studies include identification of an animal model for nasal challenge with HRSV in order to evaluate the influence of dietary feeding on HRSV pulmonary infection; and determination whether feeding HRSV neutralizing antibody and/or other neutralizing compounds can prevent or mitigate pulmonary infection in the animal following nasal challenge with HRSV. A positive outcome with an animal model will eventually permit clinical evaluation of a liquid product enhanced with an HRSV neutralizing compound.
Animals and diet: Thirty day old inbred cotton rats (Sigmodon fulviventer) free of serum neutralizing antibody against human respiratory syncytial virus (HRSV) will be used. The rats are to be fed a basal liquid diet consisting of infant formula for two days before experiments begin. One day before intranasal inoculation of virus the experimental diets will be provided. Food intake and body weight change are to be monitored daily. Upon completion of the study, all rats will be killed by carbon dioxide asphyxiation and nasal and lung tissue will be removed for analysis.
Virus: The virus to be used is human respiratory syncytial virus subgroup A2 (HRSV/Long). The virus will be prepared by infecting monolayers of HEp-2 cells, which will be grown until the monolayers show approximately 9-% syncytia formation. The medium from the monolayers will be collected, pooled and clarified by centrifugation at 450×g. Clarified supernatant fluid will be passed through a 0.45 μM filter. This supernatant will contain human respiratory syncytial virus (HRSV) at 106 PFU/ml as determined by plaque assay.
Antibodies: Polyclonal HRSV antibodies (HRSVIG) obtained commercially (Sandoz, East Hanover, N.J.) will be incorporated into liquid diets at varied concentrations and the in vitro neutralizing activity of the experimental diets supplemented with HRSVIG will be determined by plaque reduction assay.
Virus titration: Oropharyngeal swabs will be taken daily before 8 a.m. from the second day of virus inoculation until the end of the experiment. HRSV antigen in all swabs will be determined. At necropsy, nasal and lung tissue will be homogenized in 10 parts (wt/vol) of Hanks balanced salt solution supplemented with 0.218 M sucrose, 4.4 mM glutamate, 3.8 mM KH 2 PO 4 , 3.2 mM K 2 HPO 4 . The resulting suspension will be used to determine virus titers by plaque assay on Hep-2 cell monolayers.
Histopathologic examination: Formalin-fixed nasal tissues and lungs will be embedded in paraffin, cut into coronal sections, stained with hematoxylineosin with periodic acid-Schiff (PAS), and examined under a light microscope. Slides will be prepared by a pathologist for whom sample numbers will be blind during microscopic examination. Histopathology of the lung stained by PAS will be scored from 0-2.0, 2.1-6.0, 6.1-10.0, 10.1-12 as defined by Piedra et al. ("Mechanism of lung injury in cotton rats immunized with formalin-inactivated respiratory syncytial virus", Vaccine 7:34-38, 1989).
Statistical analysis: Single-tail X 2 will be used to compare proportions of the measurements between independent groups. Analysis of variance will be used to compare virus titers and severity of lung injury.
Example: Study to examine the dose-response relationship between dietary human respiratory syncytial virus immunoglobulin (HRSVIG) and human respiratory syncytial virus (HRSV) infection
Piazza et al. ("Immunotherapy of respiratory syncytial virus infection in cotton rats (Sigmodon fulviventer) using IgG in a small-particle aerosol", Journal of Infectious Disease 166:1422-1424, 1992) have shown that HRSVIG at 5 mg/100 ml solution, administered for 15 minutes in a small-particle aerosol three days after intranasal inoculation of cotton rats with HRSV, reduced virus titer 50-fold. The present study is designed to determine whether oral administration of HRSVIG can similarly reduce pulmonary infection. This will be done by incorporating an anti-RSV IgG into a liquid diet at various concentrations, after which the in vitro neutralizing activity of the experimental diets will be determined with the plaque reduction assay as described by Prince et al. ("The pathogenesis of respiratory syncytial virus infection in cotton rats", American Journal of Pathology 93:771-792, 1978).
For the study, 70 rats will be divided into 7 treatment groups. Treatment group 1 will comprise 10 rats and will serve as a negative control. They will be fed the basal liquid diet and inoculated with 0.1 ml of supernatant from HEp-2 cell culture medium which lacks cells or HRSV. Ten rats in each of treatment groups 2, 3, 4, and 5 will be fed the basal liquid diet supplemented with HRSVIG at 0, 0.5, 5, and 10 mg/100 ml respectively. Assuming that each rat will consume 100 ml of liquid diet, the anticipated daily dose for rats in each group should be 0, 0.5, 5, and 10 mg HRSVIG. Rats in treatment groups 6 and 7 will be fed the basal liquid diet supplemented with other agents to be tested for anti-respiratory virus properties. One day after consuming the experimental diets, rats in treatment groups 2-7 will be inoculated intranasally with HRSV/Long using 0.1 ml of virus suspension containing HRSV at 10 3 PFU/ml (plaque forming units). All rats will continue consuming their assigned diets until termination of the study. Four days after being challenged with the virus, all rats will be killed and nasal tissues and lungs will be removed for sequential analysis.
An effective concentration of the respiratory virus neutralizing antibody can be added to a liquid product. In a specific embodiment of the invention the liquid product is an infant formula that can be fed to an infant during the first year of life, the period when the infant is most vulnerable to RSV infection. Infant nutritional formulations could be in powder form for reconstitution with water, a ready-to-feed liquid, or a concentrated liquid. It should be understood, however, that the scope of the present invention is not to be limited to these specific embodiments. The invention may be practiced other than as particularly described and still be within the scope of the accompanying claims.
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A method of treating pneumonia or other respiratory disease caused by respiratory syncytial virus, adenovirus, parainfluenza virus, or influenza virus by orally administering a liquid, preferably an infant formula, containing a virus neutralizing antibody.
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BACKGROUND OF THE INVENTION
The invention relates to a device for the illumination of the stope supports in a longwall face. In the customary manner and necessary each stope support in a longwall face is provided with light sources by means of which the stope support and bordering longwall face can be illuminated. Since it must be assumed that a longwall face has 100 stope supports or more, it is obvious that the illumination of the stope supports requires a significant complexity which is made all the more difficult since, for reasons of safety technology, the power supply voltage for the illumination elements must be low in order to avoid sparking during switching.
The objective of the invention is to equip the device for the illumination of the stope supports with little complexity in such a manner that the device is safe.
BRIEF SUMMARY OF VARIOUS EMBODIMENTS
The special feature of this realization consists of the fact that the present equipment of the stope supports and the system controller is utilized and that in particular the supply lines carrying voltage and voltage transformers and, in given cases, rectifiers are superfluous. In this way the control power supply units required for the supply of power, which consist of voltage transformers and rectifiers and serve to supply power to the system controllers, are simultaneously also utilized to supply power to the light sources.
In this connection it is to be emphasized that, in the manner customary for the purposes supplying power, the system controllers are combined in groups, e.g. of three system controllers, and each group is supplied by one control power supply unit. This control power supply unit then also serves to supply power for illumination and in fact preferably to supply power for illuminating those stope supports whose system controllers are supplied by the control power supply unit.
In so doing, the invention makes use of the insight that, for one thing, the control power supply units must, for reasons of safety technology, have a nominal current which is substantially greater than the expected demand for power of the system controllers connected. This is associated with the peculiarity of the system controllers that, through the input of commands at a system controller, only the operation of one of its neighboring system controllers is possible so that the demand for power of the system controller serving to input the commands is, at most, low. According to the invention the free capacity of the control power supply unit is utilized to illuminate the system controller serving for the input of the commands and possibly also the system controllers operated. On the other hand, a simultaneous activation of all the system controllers connected to the same control power supply unit can be done by remote control or by automatic operation, i.e. without the presence of a human operator at the stope supports in question, so that illumination of these stope supports is not required. A special feature of the invention consists of the fact that the illumination is done only in the low-voltage range (no more that 60V) and preferably in a voltage range which also serves as the control voltage, e.g. 12 V.
The extension of the invention provides that LEDs, i.e. light-emitting diodes, are used as light sources, said LEDs today ensuring good illumination with white light and low demand for power. The use of the LEDs permits long-term operation of the light sources in the extension of the invention according to claim 3 without impairment of the illumination which, in given cases, would have to be accepted in the bargain with light sources which consume more power.
The extensions of the invention serves the purpose of always illuminating operated system controllers so that the process in the longwall face is always visible to the operator.
The extensions of the invention serve the purpose of avoiding an overload of the control power supply unit due to the demand for power of the light sources, even when control power supply units of relatively low nominal power are used with relatively low nominal current.
To avoid overloading the control power supply unit one provides, in the common supply line between the control power supply unit on one side and the individual system controller and the corresponding illumination on the other side, a current-limiting device through which the illumination is switched off on overshoot of a certain fixed maximum current or is throttled so that the power required for the system controller is always available and failure of the control power supply unit is not to be feared.
In the extension of the invention, on the one hand, an overload of the control power supply unit and, on the other hand, the shifting, or any other movement, of a stope support when a person is present is avoided. This is based on the insight that, when a person is present at a stope support, that stope support may not be pushed back so that, for reasons of safety, the system controller corresponding to the same stope support is locked and switched off during the switching of a light source. The illumination is therefore done when needed, i.e. when a person is present. In the development according to the claim, this switching on of the light source can be done by hand by the operator at the respective system controller or the associated stope support.
It can however also be done by presence detectors, e.g. motion detectors. In this case the presence detector has a double function, namely the switching on of the light source and the switching off of the system controller which an operator approaches.
In the development of the invention, on the one hand, complexity in the high-voltage system is avoided since the high-voltage system serving for the control power supply units is also utilized for illumination. On the other hand, the control power supply unit can be designed with weak nominal power and the long-term operation of the illumination in the entire longwall face, i.e. at all the stope supports, can be made possible by one light power supply unit. This light power supply unit is preferably combined with the control power supply unit.
The good illumination of a stope support also depends on the number of light sources. Through the extension of the invention the capability is provided of supplying a greater number of light sources from one control power supply unit or light power supply unit without increasing its nominal power or causing an increased demand for power which, in given cases, leads to the failure of the power supply unit or to the switching off of the illumination.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
After the above heading, please insert the following:
FIG. 1 depicts a longwall face in accordance with an exemplary embodiment of the present invention;
FIG. 2 depicts a longwall face in accordance with an exemplary embodiment of the present invention;
FIG. 3 depicts a longwall face in accordance with an exemplary embodiment of the present invention;
FIG. 4 depicts a longwall face in accordance with an exemplary embodiment of the present invention; and
FIG. 5 depicts light sources in accordance with an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
In the following the invention is described with the aid of embodiment examples and figures.
Out of the more than 100 stopes of a longwall face, only the system controllers 1 to 7 of the corresponding stope supports are represented in the FIGS. 1 to 4 . These system controllers are supplied in groups of three per piece, e.g. 1-3 or 4-6, by a common control power supply unit 8 . The control power supply unit 8 transforms the voltage of 220 V in the line 10 down to 12 DC V in the supply line 9 . The control line 11 , and simultaneously the light line 12 through which the three light sources 13 , 14 , and 15 are supplied, branch off from the supply line 9 .
The system controller devices 1 to 7 are connected to one another via a bus line 18 . Via the bus line 18 an activation of every single one of the system controllers 1 to 7 can occur, and in fact by command input at a central control room or at one of the neighboring system controllers. The current flowing in the supply line 9 is measured by a current-measuring device 16 . The current-measuring device 9 switches, via the priority line 17 , the priority switch 20 which is disposed before the light sources 13 , 14 , and 15 . The priority switch 20 is switched on in normal operation and is switched off if, in the current-measuring device 16 , a current is measured which exceeds the limit value defined as permissible. For example, the sum of the nominal current of the three light sources 13 , 14 , and 15 can be defined as a current limit value of this type. That would mean that the illumination of the light sources 13 , 14 , and 15 is switched off by means of a priority switch 20 as soon as one of the system controllers 1 , 2 , 3 or 4 , 5 , 6 etc. is activated, that is, has a need for power. The limit value in the current-measuring device 16 can however also be set higher, and in fact by the demand for power of two system controllers higher than the sum of the nominal current of three light sources or the illumination of three stope supports. Thereby the fact is taken into account that the system controllers provide a lock in the sense that the system controller is not actuated, and thus the assigned stope support cannot be pushed back or otherwise moved, if a person is in the area of the stope support, for example, an operator who gives control commands from the system controller. The locking therefore means in particular that from a system controller switching commands for the same stope support cannot be initiated. The circuit can also be embodied so that not all, but rather only a few, light sources are assigned, and can be switched off, by priority switches.
Conversely, the current measurement by the current-measuring device 16 can also be utilized to switch on a switch 20 which in this case takes the place of the priority switch 20 . Thereby the light sources 13 , 14 , and 15 of three neighboring stope supports can be switched on if, at one of the system controllers which are assigned to these stope supports, power is being consumed, that is, there is an operation, a shifting, or other movement of a stope support there. In other respects FIG. 1 , and the description corresponding thereto, also relates to such an embodiment. It is a prerequisite for this embodiment that the control power supply unit is designed to be so large that its nominal current exceeds the sum of all the consumers, i.e. system controllers and light sources, connected to the control power supply unit, as is the case in the embodiment according to FIG. 3 . In the system controllers according to FIG. 2 each system controller 1 , 2 , 3 , . . . , 7 is assigned a presence detector 21 with a switching device 22 . If the presence detector responds, the relevant system controller is deactivated via the locking line 23 so that through the system controller the assigned stope support cannot be shifted or otherwise moved.
The light source 13 or 14 or 15 is switched on simultaneously. In FIG. 2 it is represented that through the light lines 12 the light sources 13 , 14 , and 15 of three neighboring stope supports can be switched on or off simultaneously if one of the presence detectors 21 responds. The presence detectors 21 register the presence of a person and, in the circuit according to FIG. 2 , lead, on the one hand, to the illumination of three neighboring stope supports being switched on when a person is present in the area of the presence detector and, on the other hand, to the activation of the stope support in whose area the person is located being switched off.
In the case of the device according to FIG. 3 no other measures for the priority power supply unit of the system controllers are provided. By the design of the power supply unit 11 it is ensured that the nominal current of each power supply is in any case greater than the sum of the maximum currents of all the system controllers and light sources which are supplied by the power supply unit. By switching a light switch 24 the light sources 13 , 14 , 15 of three neighboring stope supports can be switched on by hand or by remote control or automatically, depending on certain commands, if at one of the system controllers which are assigned to these stope supports power is being consumed, that is, there is an operation, a shifting, or other movement of a stope support.
In the embodiment according of FIG. 4 also no measures for the priority switching of the system controllers are provided, but rather the power supplies are divided in two and consist of a control power supply unit 8 and an illumination power supply unit 25 . The system controllers are supplied by the control power line 11 while the light power line 12 is connected to the illumination power supply unit. The advantage of this embodiment consists of the fact that in fact only one supply line 10 with high voltage, e.g. a 220V line, to both power supplies is required but the two power supplies can be designed with relatively low nominal current which must take into account only the demand for power of the system controllers on the one hand and the light sources on the other hand.
In FIG. 5 it is represented schematically that the light sources 13 or 14 or 15 each consist of several LEDs. Let it be noted that, in all the circuits according to FIGS. 1 to 4 , this embodiment can replace the light sources 13 , 14 , 15 represented there.
It is furthermore represented that each light source 13 , 14 , 15 consists of two groups, each of the three LEDs. Both groups are supplied by a common light line 12 , but with the interposition of an inverter 26 which generates an AC voltage. The one group of LEDs is for positive voltage and the other group for negative voltage. With the appropriate choice of the frequency, of e.g. 100 Hz, there is no influence of the quality of illumination here but possibly a better utilization of the electrical power available for illumination.
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The light sources for illuminating the stope support at a longwall face are operated at low voltage, connected to the control network device, for low voltage supply of the system controllers. LEDs are particularly suitable as light sources. Measures for avoiding an impairment of the function of the system controllers are disclosed.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the field of apparatus for ophthalmic surgery. More particularly, the present invention relates to the field of apparatus for cataract surgery.
2. Description of the Related Art
With today's modem cataract surgery, it is routinely necessary to incise the anterior lens capsule of the crystalline lens of an eye to provide an opening on the anterior lens capsule so that the cataractous opaque lens can be removed. However, the anterior lens capsule of the eye is shielded by the corneal tissue. Therefore, before any cataract surgical apparatus can reach the anterior lens capsule of the eye, a passage wound has to be cut in the corneal tissue.
The following prior art patents are found to be related to the field of surgical apparatus used in cataract surgeries:
1. U.S. Pat. No. 4,959,070 issued to McDonald on Sep. 25, 1990 for "Intraocular Lens Implantation" (hereafter referred to as the "McDonald Patent").
2. U.S. Pat. No. 4,844,065 issued to Faulkner on Jul. 4, 1989 for "Intraocular Lens Inserting Tool and Methods" (hereafter referred to as the "/Faulkner Patent").
3. U.S. Pat. No. 4,785,810 issued to Baccala et al. on Nov. 22, 1988 for "Intraocular Lens Folding And Insertion Apparatus" (hereafter referred to as the "Baccala Patent").
4. U.S. Pat. No. 4,766,897 issued to Smirmaul on Aug. 30, 1988 for "Cataract Surgical Instrument" (hereafter referred to as the "Smirmaul Patent").
5. U.S. Pat. No. 5,135,530 issued to Lehmer on Aug. 4, 1992 for "Anterior Capsular Punch with Deformable cutting Member" (hereafter referred to as the "Lehmer Patent").
In the above five prior art patents, three of them, the Baccala Patent, the Faulkner Patent and the McDonald Patent, are not anterior lens capsule incising apparatus, but rather intraocular lens implanting apparatus. An anterior lens capsule incising apparatus is used in cataract surgery for cutting an incision on the anterior lens capsule of an eye, so that the natural lens of the eye can be removed and an artificial intraocular lens can be implanted therein. Alternatively, an intraocular lens implanting apparatus is used in the cataract surgery for inserting the artificial intraocular lens into the lens capsule of the eye, after the incision is cut on the anterior lens capsule of the eye and the natural crystalline lens of the eye is removed. The apparatuses envisioned by the Baccala Patent, the Faulkner Patent and the McDonald Patent are each more like a forceps apparatus because none of them contain cutting blades for performing the function of cutting the incision on the anterior lens capsule of the eye.
The Smirmaul Patent apparatus 10 is an anterior lens capsule incising apparatus. Its forward portion, including the circular lens holder 18, can be inserted through a passage wound cut on the corneoscleral tissue of an eye, and disposed above the anterior lens capsule of the eye, so that its rotatable cutting blade 20 can cut a circular incision on the anterior lens capsule. The Smirmaul Patent incising apparatus 10 requires a wide passage wound cut on the corneoscleral tissue. The diameter of the rotatable circular cutting blade 20 of the Smirmaul Patent incising apparatus 10 is about six millimeters (6 mm) (Column 3, line 23), which is the necessary size for cutting an adequate incision on the anterior lens capsule for further surgeries. Therefore the overall diameter of the circular blade holder is at least above seven millimeters (7 mm). This requires that the width of the passage wound cut on the corneoscleral tissue to be not less than seven millimeters (7 mm), which is wide by eye surgery standards. It is desirable to have the width of the passage wound cut on the corneoscleral tissue as narrow as possible, since a wider wound requires more surgical closing procedures and increases the period of convalescence.
The Lehmer Patent discloses an annular capsular punch with a deformable cutting member. A cutting member 130 is elliptical when inserted through an incision 16 on the corneoscleral tissue of the eye. Once the cutting instrument 130 is in the anterior chamber of the eye, it is allowed to expand a circular shape and then pressed against the anterior lens capsule of the eye.
According to the Lehmer patent, the circular shape would have a circular cutting blade having a diameter of not less than five millimeters (5 mm). Additionally, the preferable anterior lens capsule incising apparatus should be able to pass through a narrow corneoscleral tissue wound having a width of not more than four millimeters (4 mm).
This deformable circular cutting ting is provided between the two forward portions of two elongated arms. The two elongated arms crisscross each other and are hinged together at the crisscross joint. The rearward portion of the two arms are spring biased to keep the forward portion of the two arms spaced apart, such that the deformable circular cutting ring is in its original circular shape. When the rearward portions of the two arms are squeezed toward each other, the forward portions of the two arms will move toward each other to compress the deformable circular cutting ring into a narrow elliptical shape.
The overall width of the narrow elliptical shaped deformable circular cutting ring and the forward portions of the two elongated arms become less than four millimeters (4 mm), so that the narrow elliptical shaped deformed cutting ting and the forward portions of the two elongated arms can be inserted into the anterior chamber of the eye through a narrow corneoscleral tissue wound of about four millimeters (4 mm) in width. The crisscross joint of the two elongated arms is located at or adjacent to the corneoscleral tissue wound.
Once inside the anterior chamber of the eye, the rearward portions of the two arms are released, so that the forward portions of the two arms can move away from each other to allow the deformable circular cutting ring return to its original circular shape. Then the full size circular cutting ring is pressed onto the anterior lens capsule to cut an adequate sized circular incision, so the natural crystalline lens of the eye can be removed, and an artificial intraocular lens can be implanted therein. The deformable circular cutting ring is taken out of the anterior chamber through the narrow wound on the corneoscleral tissue by again compressing it into a narrow elliptical shape.
Also, a locking mechanism is to be provided to the anterior lens capsule incising apparatus for preventing the deformable cutting ring from rotating about its axis, so that the cataract surgeon can control the exact orientation of the deformable cutting ring and the cutting edge of the deformable cutting ring is evenly applied on the anterior lens capsule.
It is desirable to provide a reliable tool for performing capsulorrhexis through a small incision cataract without the unpredictability, inconsistency and unreliability of capsulorrhexis performed with a cystatome and/or capsulorrhexis forceps and which operates in a manner different from conventional teachings of tools for carrying out a capsulorrhexis.
SUMMARY OF THE INVENTION
One aspect of the present invention resides in a capsulorrhexis instrument that is retractable within a tube and extendable into a position projecting out of the tube. The instrument comprises a flexible band having a razor sharp cutting edge which is fixed to a plunger and located within an inserter tube. While in its retracted position within the inserter tube, the flexible band assumes an elliptical or oblong shape. However, when the flexible band is in its extended position outside of the inserter tube such as inside the eye, it deforms into a circular shape whose cutting edge is sufficiently sharp to cut corneal tissue in response to pressure being applied to the corneal tissue by the cutting edge. The dimension to which the flexible band expands to reach the circular shape upon becoming clear of the inserter tube is larger than a cross-section of the gap defined by the inserter tube through which the flexible band travels in its elliptical or oblong shape.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, reference is made to the following description and accompanying drawings, while the scope of the invention is set forth in the appended claims.
FIG. 1 is a schematic representation of a capsulorrhexis instrument in accordance with the invention with its band in a retracted position.
FIG. 2 is a schematic representation of the instrument of FIG. 1 except with its band in an extended position.
FIGS. 3-5 are progressive schematic representations of the capsulorrhexis instrument of FIGS. 1-2 in use showing the flexible band in, respectively, the retracted position, the extended position and the retracted position after cutting.
FIG. 6 is a perspective view of the flexible band with dye.
FIG. 7 is a schematic elevational view of a further embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show an introducer tube 10, a plunger housing 12, and plunger 14, and a spring 16 that biases the head disc 18 within the plunger housing 12. A stem 20 extends from the head disc 18 and a flexible band 22 is connected to the free end of the stem 20.
The operation of the plunger within the plunger housing is in accord with conventional teachings in other arts. The flexible band, however, changes from an elliptical or oblong configuration when residing within the introducer tube in the fully retracted position of FIG. 1 to a circular configuration while emerging free of the introducer tube to reach the fully extended position of FIG. 2.
The flexible band 22 is normally in the circular condition while in an uncompressed state, but resiliently flexes into the elliptical or oblong condition when squeezed into the introducer tube that has a smaller cross-section. The flexible band may be constructed of metal or any other material with at least one razor sharp edge 24 as identified in FIG. 6. Preferably, the other edge is smooth.
The plunger may be plastic or metal construction. The plunger housing 12 serves as a handle for a surgeon to hold onto. The inserter tube may have an inner diameter of 11/2-3 mm and the flexible band in its circular configuration may have a 4-8 mm inner diameter.
Before an incision 30 can be cut on the anterior lens capsule 32 of an eye for removing the natural crystalline lens of the eye and implanting an artificial intraocular lens therein, a small wound 34 must be cut on the corneoscleral tissue 36 of the eye to gain access to the anterior chamber of the eye, which anterior chamber is shown in FIGS. 3 through 5 by the space between the anterior lens capsule 32 and the corneoscleral tissue 36. It is preferable to have a small and narrow corneoscleral wound 34, preferably not more than three millimeters (3 mm) in width. However, the size of the anterior capsular incision 30 should be no less than five millimeters (5 mm). The present invention solves this problem by utilizing the deformable flexible band 22 with a sharp edge 24.
In addition, a viscoelastic material, such as Healon™, Amvisc™, Viscoat™ or Vitrax™, must be injected to fully expand the anterior lens chamber prior to use of the capsulorrhexis instrument, as is done conventionally. Such chamber expansion is needed before the surgery can be performed to avoid tissue damage as the flexible band is inserted into position for cutting.
To insert the flexible band 22 into the anterior chamber of the eye, the flexible band 22 is initially retracted within the introducer tube 10 as the distal end of the introducer tube is inserted through the narrow corneoscleral wound 34. Thereafter, the plunger 14 is forced against spring bias to force the flexible band 22 out of the introducer tube 10 and into the anterior chamber of the eye but clear of the narrow corneoscleral wound 34. Once so free, the flexible band 22 resiliently flexes from the elliptical shape to return to its original circular shape.
As the deformable flexible band 22, now circular in shape, is accurately located above the anterior lens capsule 32 of the eye, a force is applied on the flexible band 22 directed perpendicular to the insertion direction via the stem 20 to cut the incision 30 to have an adequate size, typically about five millimeters (5 mm) in diameter. This cutting process is done while keeping the distal end of the introducer tube 10 at or adjacent the narrow corneoscleral wound 34, so that further swings of the introducer tube will not require a wider wound. To effect the cutting, the surgeon presses on the anterior lens capsule, thereby providing the force through anterior lens capsule that is necessary for the sharp edge to cut.
If desired, a non-toxic dye 35 such as fluorescein may be applied to the sharp edge 24 to serve as a marker for the surgeon as to where the cut was made (see FIG. 6). Thus, as the sharp edge comes into contact with tissue to effect cutting, the dye comes off and onto the tissue, thereby leaving a visual imprint along the boundary of incision 30 (see FIG. 5).
After the incision 30 is made, the plunger 14 is released (e.g., via spring bias) into the introducer tube 10 so as to form the flexible band 22 by compressing the flexible band 22 into the narrow elliptical shape. Once the plunger is fully retracted, the introducer tube 10 can be withdrawn from the anterior chamber through the narrow corneoscleral wound 34. The flexible band 22 and introducer tube 10 are intended to be disposable as a single use item.
An advantage of the present invention lies in that the introducer tube may have a width of as small as 11/2 mm, easily fitting within incisions as small as 2.5 mm. In the past, incisions were typically in the order of 4 mm, which gave extra room to accommodate capsulorrhexis instruments of larger dimensions. However, with incisions as small as 2.5. mm, the need for smaller dimensioned capsulorrhexis instruments is apparent, particular when one considers that incisions in the future will be still smaller in size.
The configuration of the capsulorrhexis instrument may be curved to accommodate performing cataract surgery from above the forehead of the patient where it may be difficult to circumvent the brow of the patient. If the cataract surgery is performed from the side of the eye of the patient, then no such curvature is needed.
There are various embodiments to aid the surgeon in knowing when the flexible band has reached its fully extended state or has been withdrawn into its fully retracted state. In all cases, full retraction would be from visual observation.
One embodiment employs a locking mechanism that locks the flexible band in the extended position as the plunger is pushed to an intermediate position (closer to the fully extended position) such as 95% of the way and that unlocks the flexible band from that extended position as the plunger is pushed the rest of the way to the fully extended position, such as the remaining 5%. This simulates the locking mechanism of a ballpoint pen by allowing the flexible band to alternate between the fully extended and fully retracted states. Starting from the fully retracted position, the plunger is pushed as far as possible until further movement is blocked at a blocking position by the mechanism and is then released. The release allows the spring bias to force the plunger into the 95% position where the flexible band is fully expanded, thereby positioning the band for cutting. When done cutting, the plunger is again pushed as far as possible until blocked, but this time release causes the spring bias to force the plunger all the way back to the fully retracted position. Such continues in an alternating manner as much as desired as in actuation of a ballpoint pen.
Another embodiment dispenses with the locking mechanism, but the plunger is blocked upon reaching full extension and this blocking is felt as a noticeable increase in resistance to pushing of the plunger. In this manner, the surgeon comes to realize that the flexible band has reached its fully expanded state. Thus, the procedure followed by the surgeon is making an incision in the eye, placing the introducer tube at or into the incision, pushing the plunger until the flexible band has emerged from the introducer tube into its fully expanded state, feeling the resistance to further movement in the direction of pushing, engaging the anterior lens capsule and pressing the same to cut tissue with the sharp edge of the flexible band, releasing the plunger to retract the flexible band back into the introducer tube, and removing the introducer tube from the eye.
Still another embodiment locks or dicks when the flexible band clears the edge of the introducer tube and a further embodiment that locks in after the plunger stem extends several millimeters into the eye to space the flexible band from the introducer tube to allow for more maneuvering of the expanded band if the surgeon wished to place the cut in a more posterior or lateral or medial position. However, for most surgeries where the incision is 2.5 mm, allowing the locking or clicking to arise as the flexible band expands at the edge of the introducer tube provides plenty of maneuverability without opening the incision further provided the introducer tube has a width of at most 2 mm.
Where the eye is particularly deep-set, however, additional maneuverability may be needed so it would be more advantageous to keep the inserter tube outside the incision and pen the band further inside the eye by a few millimeters with a longer and curved plunger stem such a curved stem as shown in FIG. 7 allows better access to the eye where the surgery is to be conducted from above the forehead as opposed to the side. To prevent the possibility of the expanded flexible band springing back inadvertently into the introducer tube while the introducer tube is outside the incision, a spring release mechanism would need to be actuated by the surgeon to release the spring.
While the preferred embodiment employs a spring bias to retract the flexible band into the inserter tube, the spring bias could instead be opposite to push the flexible band out of the inserter tube. Also, the spring could be dispensed with altogether, but such would require greater dexterity on the part of the surgeon to steady the inserter tube in its relative position to the eye as the flexible band is either pulled into the inserter tube or forced out. The inserter tube may be of uniform dimension along its full length, such as having an inner diameter of about 2 mm. The inserter tube need not be narrower at its distal end through which the flexible band emerges or retracts. If a spring is to be used, however, an inwardly directed projection about the inner periphery at an intermediate location of the inserter tube is needed to provide the spring with a surface against which it may compress. Of course, a wider proximal end is more advantageous for grasping purposes.
While the foregoing description and drawings represent the preferred embodiments of the present invention, it will be understood that various changes and modifications may be made without departing from the spirit and scope of the present invention.
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A capsulorrhexis instrument that is retractable within a tube and extendable into a position projecting out of the tube. The instrument comprises a flexible band having a razor sharp cutting edge which is fixed to a plunger and located within an inserter tube. While in its retracted position within the inserter tube, the flexible band assumes an elliptical or oblong shape. However, when the flexible band is in its extended position outside of the inserter tube such as inside the eye, it expands into a circular shape whose cutting edge is sufficiently sharp to cut lens capsular tissue in response to pressure being applied to the lens capsular tissue by the cutting edge. The dimension to which the flexible band expands to reach the circular shape upon becoming clear of the inserter tube is larger than a cross-section of the gap defined by the inserter tube through which the flexible band travels in its elliptical or oblong shape.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to barriers for the protection of reserved areas against intrusion by motor vehicles.
2. Description of the Prior Art
"Reserved areas" are to be taken to mean areas for the parking of private vehicles, or so-called individual parking spaces, conferring upon their owners a right of private use, or areas for circulation intended for the sole use of pedestrians or authorized vehicles, such as pavements, avenues, alleys or lanes, for example. In such cases, protective barriers are provided to prevent access to these areas by all unauthorized vehicles. "Reserved areas" are also to be taken to mean surface areas occupied by trees, posts of the signpost type, poles carrying carrying electric cables, telephone poles, telegraph poles, pylons and the like and, in these cases, the said barriers are specially designed and located so as to prevent any damage resulting from shocks or bumps caused by machines, vehicles or others.
Thus, for example, in the case of indivual parking spaces or entries to private roads or drives, these barriers generally take the form of devices firmly anchored in the ground which are able to occupy two extreme positions, namely: an upright position and a lying position. The upright position corresponds to the position preventing access to the reserved area by any vehicle, while the lying position permits such access. These two positions are attained as a result of pivotal movements imparted to the said devices, and they can be blocked using any appropriate means so as to prevent an external event or an authorized party from modifying them. The owners of private parking spaces thus have at their disposal locking or blocking means giving them alone the ability to operate the said barriers. However, it frequently happens that these devices are subjected, deliberately or unintentionally, to shocks and that, as a result, they are damaged to the extent of becoming unusable and of having to be removed and replaced, which involves quite a substantial investment. The same applies to barriers designed for the protection of trees, posts and the like, which barriers are placed around these trees or posts so as to form obstacles preventing their damage by violent bumps or shocks.
SUMMARY OF THE INVENTION
The present invention aims to avoid these drawbacks and to enable these devices to withstand or absorb shocks without this necessarily resulting in the need to proceed to the said removal and replacement.
For this purpose, the invention provides a barrier comprising at least one vertical element pivotally mounted on a sole anchored in the ground, and characterized by the arrangement, between the said sole and the said vertical element, of an elastically deformable means having at least one spring extending between a terminal zone integral with the said sole and a zone engaging with the said element.
Such an elastically deformable means can easily be designed, on one hand to absorb any shocks or thrusts, the whole resisting passage across this element by any vehicle without the latter sustaining damage and, on the other hand, to bias the said element back to its normal protective position.
According to one possible form of embodiment suitable for barriers to protect individual parking spaces or reserved circulation areas, the said element articulated at its base consists of a post and acts against the said elastically deformable element with which it is associated when it is biassed in the direction opposite that of normal swinging towards a lowered rest position, and a means is provided for limiting the amplitude of the deflection resulting from this biassing;
the base of the said articulated element is rotationally mounted about a horizontal pin, the ends of which form pivots supported by bearings provided in a shoe or housing borne by the sole that is to be anchored in the ground, and this same base is adapted to act directly in compression upon a spring provided on the said sole when a thrusting force is exerted in the direction opposite that bringing the said post into its normal lowered position;
the height of the assembly in raised position is adapted to remain greater than the height in relation to the ground of the chassis of a vehicle to be parked in the parking space or able to use the reserved circulation area the entry to which it defends.
According to another possible form of embodiment, the said element articulated at its base consists of a post on the upper portion of which are provided loop-like members projecting laterally and arranged in the same plane, the bases of these loop-like members being connected to the said post via springs.
In one form of embodiment suitable for constituting a protective barrier for trees, pylons or the like, the said element consists of a post articulated at its base and capable of swinging in all directions, the said elastically deformable element being formed by at least one coil spring extending between a terminal zone integral with the said base and a complementary zone engaging with the said post.
According to one possible form of embodiment, the said post comprises, laterally, projecting elements forming substantially the arc of a circle to encircle the tree, pylon or the like partially or entirely.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the invention will emerge more clearly from the following description, provided with reference to the annexed drawings, wherein:
FIG. 1 is a front cross-sectional and elevation view of an example of an improved barrier according to the invention in a raised position;
FIG. 2 is a side view;
FIG. 3 is a view corresponding to FIG. 2, the barrier being in a lying position;
FIG. 4 is a view corresponding to FIG. 2, the barrier being in an extreme position possible through the effect of an antagonistic thrust;
FIG. 5 is a view analogous to that of FIG. 1, illustrating a variant;
FIG. 5A is a cross-sectional view along line VA--VA of FIG. 5;
FIG. 6 is a cross-sectional view along line VI--VI of FIG. 5;
FIG. 7 is an exploded perspective view of the constituent elements of the device featuring in the upper portion of FIGS. 5 and 6;
FIG. 8 is an elevational view of a variant of a barrier according to the invention;
FIG. 9 is a plan view along line IX--IX of FIG. 8, and
FIG. 10 is a plan view, on a smaller scale, of a variant of the barrier as a whole.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the first chosen form of embodiment, shown in FIGS. 1 to 4, a barrier according to the invention is constituted by an upright 1 having the form of a metallic post with a rectangular cross-section. Through the base of this post passes a cylindrical part 2, the ends 3 of which form journals borne by bracket-bearings 4. This assembly can be received in a housing 5. The latter is welded to a sole , which is firmly anchored in the ground G, for example by bolts 7. The upper portion of the housing 5 comprises a recess 8 for angular deflection of the post 1 between a raised (vertical) position illustrated in FIGS. 1 and 2, and a lying position, illustrated in FIG. 3. A return spring 9 is attached between pin 2 and a stud 9A provided for this purpose on a slide 10 mounted in post 1 with liberty of translation parallel to the longitudinal axis of the post limited by a stud and slot coupling 11-12 formed by the stud 11 borne by the said post 1 and the slot cut out in the slide 10. The upper portion of the latter ends in a hook, handle or nose 13 which can be immobilized in a desired position thanks to a key operated system schematically represented at 14 (FIG. 1), which can be of any known type or designed as illustrated and described hereinafter with reference to FIGS. 5 to 7. As to the lower portion of the said slide, this is extended by an elongated part 15 playing the part of a bolt designed to cooperate with a striking box, formed here by a cavity 16 hollowed out in the ground and opening into sole 6. The width (a) of this cavity corresponds substantially to the width of the said part 15, while its length is established according to the maximum deflection that is allocated to the post 1 in the event of a thrust in the direction of arrow F1 (FIGS. 2 and 4), as will be seen below.
Furthermore, the vicinity of the lower portion of post 1 comprises a piece in the form of a heel 17 designed to cooperate with a leaf spring 18 possessing high bending strength mounted on plate 6 via a shoe 19 and bolted (or welded) to the said plate.
With such an assembly, it will be noted immediately that if, after acting on key operated system 14, slide 10 is pulled upwards, bolt 15 is removed from cavity 16 in which it was previously engaged, which enables post 1 to be swung in the direction of arrow F2 to cause it to occupy the lying position illustrated in FIG. 3. In this position, it will be noted that return spring 9 has been extended as a result of the translation movement performed by slide 10 in the direction of arrow F3 up to the position at which the lower end of slot 12 comes into abutment against stud 11. The assembly can remain held in this spring tensioning position by means of the key operated system 14. To return to the upright position illustrated in FIGS. 1 and 2, it suffices to release slide 10, so that, through the action of spring 9, it is biassed in the direction of arrow F4. In the raised position, illustrated in FIGS. 1 and 2, the bolt 15 then drops back into striking box 16, and it can be locked in this position by means of the lock formed by the key operated system 14. The assembly bears on the wall of cavity 16 and on a stop 16A provided on the sole 6 as an extension of the said wall.
It is also possible to release the slide by allowing spring 9 to become slack when the post is in the lying position: during the movement of raising to the upright position, bolt 15 can come into contact with the upper face of stop 16A, but it can be raised without difficulty by exerting tension on spring 9 until it arrives opposite the striking box, into which it will drop automatically through the effect of the release of the said spring.
If, in the upright position, post 1 is subjected to thrust or to a shock (arrow F1) in the direction opposite that tending to bring it into the lying position (arrow F2), heel 17 bears heavily on leaf spring 18, which yields, while absorbing the force applied. To limit the deflection of the post under the effect of such thrust, two elements will act as stop means, namely the full bearing of heel 17 on leaf spring 18, on one hand, and the abutment of bolt 15 on the transverse wall of striking box 16 which is opposite its normal bearing position. Forcible entry of the parking area as a result of the post swinging fully in the direction of thrust F1 is thus prevented. Such a limitation of swing has the effect of leaving mechanical parts above ground level at a height at least equal to the height of the chassis of a vehicle in relation to the ground; consequently, there is a risk of collision and damage to a vehicle attempting to force its way through. That is why the post in question will be designed to have a height such that, even when inclined at an angle of 45°, for example (as illustrated in FIG. 4) this chassis height is maintained.
The above description relating to the design of the lower portion of a parking area barrier brings out, as it is, the advantage and value of the improvement thus made. A post that has been subjected to stress or a shock can return to its initial raised position and continue to play its role as a means of protection against an unauthorized access attempt, without necessitating systematic replacement.
This improvement is complemented by the improvement also made to the upper portion of a barrier of the post type such as the one described above and comprising, laterally and so as to project, elements constituting the desired space occupying volumes or surfaces.
In the form of embodiment illustrated here, these space occupying volumes or surfaces are represented by two lateral loop-like members 20, 21. These loop-like members can be produced using any material, preferably tubular and, according to the invention, they are connected to post 1 via sections of appropriate lengths of helicoidal springs 22 and 23 passing freely right through the said post. A portion of these springs fits into tubular elements 20 and 21, and they are secured by crimped points such as 24, 25. To complete such an assembly, reinforcing plates, such as 26 can be provided, these being, for example, welded or riveted.
Thanks to such an arrangement, any shock or thrust applied to the loop-like members results in yielding, generally preventing any damage liable to necessitate replacement of the barrier.
It can thus be seen that a barrier according to the invention receiving a shock or being subjected to frontal or lateral thrust is able to withstand and absorb this shock or thrust without damage, given the flexibility and ability to be deformed without damage imparted to the barriers according to the invention equipped with the means described.
According to one possible form of embodiment, cavity 16 can be dispensed with by causing part 15 to end at the sole 6, part 16, possibly raised, sufficing to serve it as a stop.
Further, for greater convenience of use, lock 14 can be placed at the top of post 1. An advantageous form of embodiment implementing such developments will be described hereinafter, with reference to FIGS. 5 to 7.
These FIGURES show: a post 1A, a sole 6A, a housing 5A, a pivot pin 2, a leaf spring 18A, bolts 7 for securing the sole in ground G, recess 8, return spring 9, slide 10A with the end portion 15 forming a bolt, and stop 16A. A lock 27, provided at the top of the post forms a security assembly (to be described hereinafter) above two lateral loop-like members 20, 21, again equipped with their springs 22, 23 passing through the said post 1 and their crimped points 24, 25.
In this form of embodiment, the need for a striking box hollowed out in the ground is avoided. Furthermore, the yielding of leaf spring 18A is obtained, here, in the event of thrust being exerted in the antagonistic direction of arrow F1, by providing at the lower end of post 1 a curved back bearing segment 17A to play the part of supporting heel 17 in the variant described previously.
Simplification of the design is also to be found in the ease with which the leaf spring can be mounted and assembled, in that this spring is held at one of its ends by a device that is simple and easy to produce and mount: in the vicinity of one of the ends, leaf spring 18 has two studs, 18B, 18B (FIG. 5A) designed to be inserted in matching recesses 18C, 18C provided in a part 1BE supported by lateral walls 5B, 5B by a tenon and mortise type system identified as 5C-5D. This leaf spring rests, furthermore, on a cross member 19A of the sole, also inserted between walls 5B, 5B by the same means of the tenon and mortise type, 19B-19C. The lateral walls 5A, 5B are in one piece, here, with sole 6A, which represents a further simplification avoiding any need for welding in the housing.
Further security is obtained thanks to the fact that the lock system is mounted at the top of the post (see FIGS. 5, 6 and 7). In this case, slide 10A to which is secured the upper end of return spring 9 (at 9A) is attached to lock 14 by a rod 9D ending in a hook shaped element 9E to which upward traction can be applied as before. Slide 10 forming bolt 15 is guided here by a plate 9C fixed to an inner face of post 1 with a raised marginal portion to ensure the said guiding and a hook 9B being formed at the bottom of this raised portion to engage the lower end of return spring 9.
Lock 27 (see FIG. 7) is installed in an area set aside for this purpose at the top of post 1 via a fitted housing 28 fixed by riveting. The lock itself, located inside the said housing, is rendered practically impregnable owing to the S fact that, into housing 28 receiving the rivets at R is fitted the barrel holder 29 in which barrel 30 is mounted by a screw 31 passing through it at 31A. This barrel holder has flats 32 adapted to be flush with the upper edge of the post and to be secured by welding to a cover 33 forming a protective plate. It will be appreciated that, mounted as it is, this lock affords no opportunity of dismantling it to gain access to the slide manoeuvering means, save by fracturing the entire upper portion inside which the said lock is housed. The turning of a key causes the rotation of a tooth (30B) on mobile portion 30A of the barrel which acts to raise, for example, catch 9E and, as a result, slide 10.
With reference now to FIGS. 8 to 10, these show a variant of the invention suitable for the protection of trees, posts and the like. A hollow post having a rectangular cross-section 1B is borne by a sole 6B, bolted to the ground G at 7.
This sole 6B has here a raised central portion 40, through which pass two anchor bolts 41, 42, each of them being adapted to make integral with the sole the lower end portion, shaped for this purpose, of a helicoidal spring 43, 44 of appropriate strength and dimensions.
The lower portion of these juxtaposed springs, which portion is confined to a few turns, is capped by the force fitting of a base 45 formed by a section of tubular bar the shape of which is similar to that of the bar forming post 1B; this fit is reinforced by a wedge 47. The post 1B itself is force fitted over the upper complementary portion of springs 43, 44 which emerges from base 45. this second fit is reinforced by a wedge 48 and by a locking pin 49 jammed between the two springs.
It will be appreciated, then, that, with such an assembly, any shock, whatever its direction, will result in an elastic reaction by the post, which will swing about the base 45, while absorbing the energy of impact through the deforming work of springs 43, 44 and the friction accompanying this deformation. Protection can be completed by providing, as in the case of the variant described previously, lateral projecting members such as 35-36 which can be made of suitable materials, have suitable dimensions and be of an enveloping shape, for example an arc shape, as illustrated in FIG. 10. This shape is suitable, as will be readily appreciated, for the protection of elements such as trees, pylons, posts and the like. If really necessary, the ends of these arc shaped projecting members can come together to encircle these elements entirely and, in this case, they can have, in particular at their point of attachment to the post, a degree of elasticity suitable for facilitating their installation.
It goes without saying that the description of the present invention has been provided solely by way of illustration and is in no way limitative, and that any appropriate modification could be made thereto without thereby departing from its scope. One essential advantage of the invention remains, in any case, the fact that elastic deformation occurring at the time of impact ensures that the sealing system formed in a single block (reference G in the drawings) is not torn out, which is, indeed, a risk in the case of the rigid systems of the prior art.
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A barrier for the protection of reserved areas including at least one upper element (1) rotatably mounted relative to a lower element (6) anchored in the ground (G). An elastic return spring (18) is interposed between the upper and lower elements (1,6). The upper element (1) is adapted to be displaced to either side of an upright reference position by rotating about a horizontal pin (2) provided on the lower element (6). A releasable mechanism selectively blocks rotation of the upper element in a first direction (F2) and a non-releasable mechanism blocks rotation of the upper element in the reverse direction (F1) at the end of a limited angular deflection. The elastic return spring provides a force opposing the limited deflection in the reverse direction.
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BACKGROUND
[0001] The present disclosure generally relates to semiconductor structures, and particularly to a semiconductor structure including multi-direction wiring for replacement gate lines, and methods of manufacturing the same.
[0002] The difficulty of printing gate patterns for technologies with a small pitch on par with lithographic minimum dimensions has led to the development of unidirectional gate patterns, i.e., gate patterns that extend only along a single horizontal direction, and prohibits extension of the gate lines in any other horizontal direction. Unidirectional gate patterns shifts the burden of signal routing to metal interconnect structures provided above the gate level, e.g., by requiring more lateral connections to be formed in contact level metal interconnect structures and/or wiring level metal interconnect structures.
SUMMARY
[0003] A post-planarization recess etch process is employed in combination with a replacement gate scheme to enable formation of multi-directional wiring in gate electrode lines. After formation of disposable gate structures and a planarized dielectric layer, a trench extending between two disposable gate structures are formed by a combination of lithographic methods and an anisotropic etch. End portions of the trench overlap with the two disposable gate structures. After removal of the disposable gate structures, replacement gate structures are formed in gate cavities and the trench simultaneously. A contiguous gate level structure can be formed which include portions that extend along different horizontal directions.
[0004] According to an aspect of the present disclosure, a semiconductor structure includes a semiconductor material portion located on a substrate, which contains a source region, a drain region, and a body region. A planarization dielectric layer overlies the semiconductor material portion. The semiconductor structure further includes a gate stack structure embedded in the planarization dielectric layer and including a gate dielectric and a gate electrode that is embedded in the gate dielectric. The gate dielectric includes a horizontal portion in contact with the body region. The gate dielectric may also include a vertical portion having outer sidewalls that define a lateral extent of the gate stack structure. The gate stack structure includes a first portion contacting the semiconductor material portion and extending along a first horizontal direction and a second portion extending along a second horizontal direction that is different from the first direction.
[0005] According to another aspect of the present disclosure, a method of forming a semiconductor structure is provided. At least one semiconductor material portion is formed on a substrate. At least one disposable gate structure is formed over the at least one semiconductor material portion. A planarization dielectric layer is formed over the at least one semiconductor material portion and the at least one disposable gate structure. A trench is formed in the planarization dielectric layer. A sidewall of a remaining portion of one of the at least one disposable gate structure is physically exposed within the trench. At least one gate cavity is formed by removing the at least one disposable gate structure. A replacement gate stack structure is formed in the at least one gate cavity and the trench.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0006] FIG. 1A is a top-down view of a first exemplary semiconductor structure after lithographic patterning of a first photoresist layer over a semiconductor-on-insulator (SOI) substrate according to a first embodiment of the present disclosure.
[0007] FIG. 1B is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane B-B′ of FIG. 1A .
[0008] FIG. 2A is a top-down view of the first exemplary semiconductor structure after formation of a plurality of semiconductor fins by patterning a top semiconductor layer of the SOI substrate according to the first embodiment of the present disclosure.
[0009] FIG. 2B is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane B-B′ of FIG. 2A .
[0010] FIG. 3A is a top-down view of the first exemplary semiconductor structure after formation of a plurality of disposable gate structures according to the first embodiment of the present disclosure.
[0011] FIG. 3B is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane B-B′ of FIG. 3A .
[0012] FIG. 4A is a top-down view of the first exemplary semiconductor structure after formation of gate spacers according to the first embodiment of the present disclosure.
[0013] FIG. 4B is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane B-B′ of FIG. 4A .
[0014] FIG. 5A is a top-down view of the first exemplary semiconductor structure after deposition and planarization of a planarization dielectric layer according to the first embodiment of the present disclosure.
[0015] FIG. 5B is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane B-B′ of FIG. 5A .
[0016] FIG. 6A is a top-down view of the first exemplary semiconductor structure after application and lithographic patterning of a third photoresist layer, and transfer of the pattern in the third photoresist layer into at least an upper portion of the planarization dielectric layer and upper portions of disposable gate structures and gate spacers according to the first embodiment of the present disclosure.
[0017] FIG. 6B is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane B-B′ of FIG. 6A .
[0018] FIG. 6C is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane C-C′ of FIG. 6A .
[0019] FIG. 7A is a top-down view of the first exemplary semiconductor structure after removal of disposable gate structures according to the first embodiment of the present disclosure.
[0020] FIG. 7B is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane B-B′ of FIG. 7A .
[0021] FIG. 7C is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane C-C′ of FIG. 7A .
[0022] FIG. 8A is a top-down view of the first exemplary semiconductor structure after formation of replacement gate stack structures according to the first embodiment of the present disclosure.
[0023] FIG. 8B is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane B-B′ of FIG. 8A .
[0024] FIG. 8C is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane C-C′ of FIG. 8A .
[0025] FIG. 9A is a top-down view of the first exemplary semiconductor structure after formation of a contact-level dielectric layer and contact via structures according to the first embodiment of the present disclosure.
[0026] FIG. 9B is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane B-B′ of FIG. 9A .
[0027] FIG. 9C is a vertical cross-sectional view of the first exemplary semiconductor structure along the vertical plane C-C′ of FIG. 9A .
[0028] FIG. 10 is a vertical cross-sectional view of a second exemplary semiconductor structure according to a second embodiment of the present disclosure.
[0029] FIG. 11 is a vertical cross-sectional view of a third exemplary semiconductor structure according to the third embodiment of the present disclosure.
DETAILED DESCRIPTION
[0030] As stated above, the present disclosure relates to a semiconductor structure including multi-direction wiring for replacement gate lines, and methods of manufacturing the same. Aspects of the present disclosure are now described in detail with accompanying figures. Like and corresponding elements mentioned herein and illustrated in the drawings are referred to by like reference numerals. The drawings are not necessarily drawn to scale. As used herein, ordinals are employed merely to distinguish similar elements, and different ordinals may be employed to designate a same element in the specification and/or claims.
[0031] Referring to FIGS. 1A and 1B , a first exemplary semiconductor structure according to a first embodiment of the present disclosure includes a substrate 8 and a first photoresist layer 37 formed thereupon. At least a topmost portion of the substrate 8 includes a semiconductor material. The substrate 8 can be a semiconductor-on-insulator (SOI) substrate, a bulk substrate, or a hybrid substrate including a bulk portion and an SOI portion.
[0032] In one embodiment, the substrate 8 can be an SOI substrate including a stack, from bottom to top, of a handle substrate 10 , a buried insulator layer 20 , and a top semiconductor layer 30 L. The handle substrate 10 can include a semiconductor material, a conductive material, or a dielectric material, and provides mechanical support to the buried insulator layer 20 and the top semiconductor layer 30 L. The thickness of the handle substrate 10 can be from 50 microns to 2 mm, although lesser and greater thicknesses can also be employed. The buried insulator layer 20 includes a dielectric material such as silicon oxide, silicon nitride, silicon oxynitride or a combination thereof. The thickness of the buried insulator layer 20 can be from 10 nm to 1,000 nm, although lesser and greater thicknesses can also be employed.
[0033] The top semiconductor layer 30 L includes a semiconductor material, which can be an elemental semiconductor material such as silicon or germanium, an alloy of at least two elemental semiconductor materials such as a silicon-germanium alloy, a compound semiconductor material, or any other semiconductor material known in the art. The thickness of the top semiconductor layer 30 L can be from 30 nm to 600 nm, although lesser and greater thicknesses can also be employed. The top semiconductor layer 30 L can include a single crystalline semiconductor material, a polycrystalline semiconductor material, or an amorphous semiconductor material. Various portions of the top semiconductor layer 30 L may be doped with electrical dopants, such as p-type dopants or n-type dopants, as needed. Different portions of the top semiconductor layer 30 L may include different semiconductor materials. In one embodiment, the top semiconductor layer 30 L includes a single crystalline semiconductor material such as single crystalline silicon and/or a single crystalline silicon-germanium alloy.
[0034] While the present disclosure is described employing an SOI substrate, embodiments employing a bulk substrate or a hybrid substrate including a bulk portion and an SOI portion are expressly contemplated herein.
[0035] The first photoresist layer 37 can be applied over the top semiconductor layer 30 L and is lithographically patterned with a first pattern. The first pattern can be a line and space pattern in which each line extends along a horizontal direction, which is herein referred to as a fin direction. In one embodiment, the first pattern can include a plurality of material portions of the first photoresist layer 37 such that each of the plurality of material portions extends along a lengthwise direction. As used herein, a “lengthwise direction” of an object refers to a direction about which the moment of inertia of the object becomes the minimum.
[0036] In one embodiment, each of the plurality of material portions of the first photoresist layer 37 as patterned can have a same lengthwise direction, which is the fin direction. In one embodiment, each of the plurality of material portions of the first photoresist layer 37 can have a same width, which is the dimension along a horizontal direction that is perpendicular to the lengthwise direction. In one embodiment, each of the plurality of material portions of the first photoresist layer 37 as patterned can have a rectangular cross-sectional area such that the lengthwise edges of the rectangle representing the cross-sectional area are parallel to the lengthwise direction. In one embodiment, the width of each of the plurality of material portions of the first photoresist layer 37 as patterned can be a minimum lithographically printable dimension, i.e., a critical dimension, which is about 32 nm as of 2013.
[0037] The plurality of material portions of the first photoresist layer 37 can be laterally spaced along the widthwise direction of the first pattern, which is a horizontal direction perpendicular to the lengthwise direction of the first pattern. The lengthwise direction of the first pattern is the lengthwise direction of the plurality of material portions of the first photoresist layer 37 .
[0038] In an alternate embodiment, layer 37 may be a masking layer generated using pitch double techniques such as Sidewall Image Transfer (SIT), and may have dimensions from about 4 nm to 30 nm, and pitches from about 10 nm to 60 nm. Pitch doubling techniques such as SIT including a mandrel, spacer, and cut process, are not described here, but are well known in the art.
[0039] Referring to FIGS. 2A and 2B , the first pattern is transferred into a top portion of the substrate 8 to form at least one semiconductor material portion. The at least one semiconductor material portion can be a plurality of semiconductor material portions. In one embodiment, the plurality of semiconductor material portions can be a plurality of semiconductor fins 30 . If the substrate 8 is an SOI substrate, the first pattern can be transferred through the top semiconductor layer 30 L by an anisotropic etch employing the first photoresist layer 37 as an etch mask. The buried insulator layer 20 can be employed as a stopping layer for the anisotropic etch. The plurality of semiconductor fins 30 can be formed directly on the top surface of the buried insulator layer 20 . If the substrate 8 is a bulk substrate, semiconductor fins formed by an anisotropic etch can be electrically isolated by forming shallow trench isolation structures (not shown) including a dielectric material and/or by forming doped wells that can be employed to form reverse biased p-n junctions. Each semiconductor fin 30 laterally extends along the fin direction, which is the lengthwise direction of the semiconductor fin 30 .
[0040] Referring to FIGS. 3A and 3B , disposable gate level layers can be deposited on the substrate 8 as blanket layers, i.e., as unpatterned contiguous layers. The disposable gate level layers can include, for example, a vertical stack of a gate dielectric layer, a disposable gate material layer, and a disposable gate cap dielectric layer. The disposable gate dielectric layer can be, for example, a layer of silicon oxide, silicon nitride, silicon oxynitride, or halfnium oxide. The thickness of the gate dielectric layer can be from 1 nm to 10 nm, although lesser and greater thicknesses can also be employed. The gate dielectric layer may be disposable or may be retained when the rest of the disposable gate stack removed. The disposable gate material layer includes a material that can be subsequently removed selective to the dielectric material of a planarization dielectric layer to be subsequently formed. For example, the disposable gate material layer can include a semiconductor material such as a polycrystalline semiconductor material or an amorphous semiconductor material. The thickness of the disposable gate material layer can be from 30 nm to 300 nm, although lesser and greater thicknesses can also be employed. The disposable gate cap dielectric layer can include a dielectric material such as silicon oxide, silicon nitride, or silicon oxynitride. The thickness of the disposable gate cap dielectric layer can be from 3 nm to 30 nm, although lesser and greater thicknesses can also be employed. Any other disposable gate level layers can also be employed provided that the material(s) in the disposable gate level layers can be removed selective to a planarization dielectric layer to be subsequently formed.
[0041] The disposable gate level layers can be lithographically patterned to form disposable gate structures. In one embodiment, a photoresist (not shown) is applied over the topmost surface of the disposable gate level layers and is lithographically patterned by lithographic exposure and development. In an alternate embodiment, a masking layer generated using pitch double techniques such SIT is used to generate gate patterns, the gate pattern in the photoresist or masking layer is transferred into the disposable gate level layers by an etch, which can be an anisotropic etch such as a reactive ion etch. The remaining portions of the disposable gate level layers after the pattern transfer constitute disposable gate structures.
[0042] Each disposable gate stack may include, for example, a stack of a gate dielectric portion 40 , a disposable gate material portion 42 , and a disposable gate cap portion 49 . Each disposable gate stack ( 40 , 42 , 49 ) can straddle one or more of the plurality of semiconductor fins 30 . Each disposable gate stack ( 40 , 42 , 49 ) can extend along a lengthwise direction, which is different from the fin direction. In one embodiment, a plurality of the disposable gate stacks ( 40 , 42 , 49 ) can extend along a same horizontal lengthwise direction, which is herein referred to as a first horizontal direction, or a first direction. In one embodiment, the first horizontal direction can be perpendicular to the fin direction. Each disposable gate stack ( 40 , 42 , 49 ) can have a pair of vertical sidewalls that extend along the first horizontal direction.
[0043] Referring to FIGS. 4A and 4B , gate spacers 56 can be formed on sidewalls of each of the disposable gate structures ( 40 , 42 , 49 ), for example, by deposition of a conformal dielectric material layer and an anisotropic etch. The conformal dielectric material layer includes a dielectric material such as silicon oxide, silicon nitride, silicon oxynitride, or a combination. Horizontal portions of the conformal dielectric material layer are removed by the anisotropic etch. An overetch can be employed to remove vertical portions of the conformal dielectric material layer from portions of sidewalls of the plurality of semiconductor fins 30 that are laterally spaced from the disposable gate stacks ( 40 , 42 , 49 ) by a lateral distance greater than the thickness of the conformal dielectric material layer. Remaining vertical portions of the conformal dielectric material layer constitute the gate spacers 56 . The gate spacers 56 can contact the top surface of the buried insulator layer 20 , i.e., can be formed directly on the top surface of the buried insulator layer 20 .
[0044] Each gate spacer 56 laterally surrounds a disposable gate structure ( 40 , 43 , 49 ). Each gate spacer 56 can be topologically homeomorphic to a torus, i.e., can be continuously stretched without creating or destroying a hole into a torus. As used herein, two objects are “topologically homeomorphic” to each other if a continuous mapping and a continuous inverse mapping exists between two objects such that each point in one object corresponds to a distinct and unique point in another object. As used herein, a “continuous” mapping refers to a mapping that does not create or destroy a singularity.
[0045] Ion implantations can be employed to form various source/drain regions 36 . As used herein, “source/drain regions” collectively refer to source regions and drain regions. Unimplanted portions of each semiconductor fin 30 are herein referred to as body regions 32 . A p-n junction, a p-i junction, or an n-i junction can be formed between each neighboring pair of a source/drain region 36 and a body region 32 . As used herein, a “p-i junction” is a junction between a p-doped region and an intrinsic region. As used herein, an “n-i junction” is a junction between an n-doped region and an intrinsic region. As used herein, an intrinsic region refers to an intrinsic portion of a semiconductor material, which does not include externally introduced electrical dopants such as p-type dopants or n-type dopants.
[0046] Referring to FIGS. 5A and 5B , a dielectric material layer can be deposited over the semiconductor fins ( 32 , 36 , 36 ′) and the disposable gate structures ( 40 , 42 , 49 ). The deposited dielectric material layer is herein referred to as a planarization dielectric layer 60 . The planarization dielectric layer 60 includes a dielectric material, which can be, for example, doped or undoped silicon oxide, silicon nitride, silicon oxynitride, or a combination thereof. In one embodiment, the planarization dielectric layer 60 includes silicon oxide. The planarization dielectric layer 60 can be deposited, for example, by chemical vapor deposition (CVD). The thickness of the planarization dielectric layer 60 as deposited can be controlled such that all portions of the top surface of the planarization dielectric layer 60 are located at, or above, top surfaces of the disposable gate cap portions 49 that are most proximal to the buried insulator layer 20 .
[0047] The planarization dielectric layer 60 is subsequently planarized to provide a planar dielectric surface 63 , for example, by chemical mechanical planarization (CMP). In one embodiment, upper portions of the disposable gate cap portion 49 can be employed as an endpoint layer during the planarization. An over-polish may be performed during the planarization so that the upper portions of each disposable gate cap portion 49 can be removed. The planarization dielectric layer 60 is subsequently planarized such that each top surface of a disposable gate cap portion 49 is physically exposed. After the planarization of the planarization dielectric layer 60 , the planar dielectric surface 63 of the planarization dielectric layer 60 can be coplanar with each top surface of the disposable gate cap portions 49 .
[0048] Referring to FIGS. 6A , 6 B, and 6 C, a third photoresist layer 77 can be applied over the planarization dielectric layer 60 , and is lithographically patterned to form at least one opening therein. The location of each of the at least one opening can be selected in regions in which an additional conductive connection is desired among the wiring pattern provided by the disposable gate stack ( 40 , 42 , 49 ). The pattern in the third photoresist layer 77 is subsequently transferred into at least an upper portion of the planarization dielectric layer 60 and upper portions of the disposable gate structures ( 40 , 42 , 49 ) and gate spacers 56 by an etch, which can be an anisotropic etch such as a reactive ion etch. A trench 69 is formed in the planarization dielectric layer 60 within each area of an opening in the third photoresist layer 77 . At least one sidewall of a remaining portion of each disposable gate structure ( 40 , 42 , 49 ) is physically exposed within the trench 69 .
[0049] Sidewalls of the trench 69 may be substantially vertical, or can be tapered. In one embodiment, all sidewalls of the trench 69 can be substantially vertical. As used herein, a surface is “substantially vertical” if a vertical plane exists from which the surface deviates by not more than three times the root-mean-square roughness of the surface. In one embodiment, the trench 69 can extend between two disposable gate structures ( 40 , 42 , 49 ), and sidewalls of remaining portions of the two disposable gate structures ( 40 , 42 , 49 ) can be physically exposed within the trench 69 . In another embodiment, the trench 69 can extend from a disposable gate structure ( 40 , 42 , 49 ) and does not extend to any other disposable gate structure ( 40 , 42 , 49 ), and sidewalls of a remaining portion of a disposable gate structure ( 40 , 42 , 49 ) can be physically exposed within the trench 69 . In yet another embodiment, the trench 69 can extend among at least three disposable gate structures ( 40 , 42 , 49 ).
[0050] In one embodiment, the plurality of disposable gate structures ( 40 42 , 49 ) can extend along the first horizontal direction, and the trench 69 can extend along a lateral direction that is different from the first horizontal direction. The lateral direction along which the trench extends is herein referred to as a second horizontal direction, or a second direction.
[0051] In one embodiment, at least an upper portion of at least one gate spacer 56 can be removed during the forming of the trench 69 . In one embodiment, the area of the trench 69 can be selected such that the trench 69 does not overlie any semiconductor material portion over the buried insulator layer 20 (such as the semiconductor fins ( 32 , 36 , 36 ′) and is laterally offset from the semiconductor material portions.
[0052] In one embodiment, the bottom surface of the trench 69 can include a recessed surface of the planarization dielectric layer 60 . In one embodiment, the bottom surface of the trench 69 can be located above the top surface of the buried insulator layer 20 . In another embodiment, the bottom surface of the trench 69 can be coplanar with the top surface of the buried insulator layer 20 . In yet another embodiment, the bottom surface of the trench 69 can be recessed below the top surface of the buried insulator layer 20 . The third photoresist layer 77 is subsequently removed, for example, by ashing.
[0053] Referring to FIGS. 7A , 7 B, and 7 C, the disposable gate structures ( 40 , 42 , 49 ) can be partially or completely removed selective to the dielectric material of the planarization dielectric layer 60 and selective to the semiconductor material of semiconductor material portions (such as the semiconductor fins ( 32 , 36 , 36 ′) above the buried insulator layer 20 . A gate cavity 59 is formed in each space from which a disposable gate structure ( 40 , 42 , 49 ) is removed. Each trench 69 is contiguous with at least one gate cavity 59 . In one embodiment, a trench 69 can be contiguous with two gate cavities 59 . In another embodiment, a trench 69 can be contiguous with one gate cavity 59 . In yet another embodiment, a trench 69 can be contiguous with at least three gate cavities 59 .
[0054] Referring to FIGS. 8A , 8 B, and 8 C, the gate cavities 59 and the trench(es) 69 can be filled with a gate stack which might include a dielectric layer and a must include a conductive material layer. The gate dielectric layer can include a dielectric metal oxide, a dielectric semiconductor oxide, or a combination thereof. In one embodiment, the gate dielectric layer can be deposited by a conformal deposition method such as atomic layer deposition (ALD) and/or chemical vapor deposition (CVD). In this case, all vertical portions of the gate dielectric layer can have a same thickness t. In one embodiment, horizontal portions of the gate dielectric layer can also have the thickness t.
[0055] Excess portions of the conductive material layer can be removed from above the top surface of the planarization dielectric layer 60 , for example, by planarization. For example, chemical mechanical planarization (CMP) can be employed to remove the portions of the conductive material layer from above the top surface of the planarization dielectric layer 60 . Portions of the gate dielectric layer may also be removed from above the top surface of the planarization dielectric layer 60 . Remaining portions of the gate dielectric layer and the conductive material layer fill the gate cavities 59 and the trench(es) 69 .
[0056] A remaining portion of the gate dielectric layer in a gate cavity 59 that is not connected to a trench 69 is herein referred to as a first-type gate dielectric 50 . A remaining portion of the conductive material layer in a gate cavity 59 that is not connected to a trench 69 is herein referred to as a first-type gate electrode 54 . A contiguous remaining portion of the gate dielectric layer that is present in a trench 69 and at least one gate cavity 59 is herein referred to as a second-type gate dielectric 51 . A contiguous remaining portion of the conductive material layer that is present in a trench 69 and at least one gate cavity 59 is herein referred to as a second-type gate electrode 58 . Each stack of a first-type gate dielectric 50 and a first-type gate electrode 54 constitutes a first-type replacement gate stack structure ( 50 , 54 ), which is a gate stack structure including a replacement gate electrode. Each stack of a second-type gate dielectric 51 and a second-type gate electrode 58 constitutes a second-type replacement gate stack structure ( 51 , 58 ), which is a gate stack structure including a replacement gate electrode. The first-type replacement gate stack structures ( 50 , 54 ) and the second-type replacement gate stack structures ( 51 , 58 ) are herein collectively referred to as replacement gate stack structures ( 50 , 51 , 54 , 58 ). In one embodiment, all vertical portions of the first-type gate dielectric 50 and the second-type gate dielectric 51 can have the same thickness t. In one embodiment, all vertical portions and all horizontal portions of the first-type gate dielectric 50 and the second-type gate dielectric 51 can have the same thickness t.
[0057] The replacement gate stack structures ( 50 , 51 , 54 , 58 ) can be simultaneously formed within the gate cavities 59 and the trench(es) 69 . The replacement gate stack structures ( 50 , 51 , 54 , 58 ) are embedded in the planarization dielectric layer 60 . Each replacement gate stack structure ( 50 , 51 , 54 , 58 ) includes a gate dielectric ( 50 , 51 ) and a gate electrode ( 54 , 58 ) that is embedded in the gate dielectric ( 50 , 51 ). Each gate dielectric ( 50 , 51 ) can include a horizontal portion in contact with a body region 32 and a vertical portion having outer sidewalls that define a lateral extent of the replacement gate stack structure ( 50 , 51 , 54 , 58 ).
[0058] The first exemplary semiconductor structure includes interconnected field effect transistors. The first exemplary semiconductor structure includes at least a semiconductor material portion (i.e., one of the plurality of semiconductor fins ( 32 , 36 , 36 ′)) including a source region (one of the source/drain regions 36 ), a drain region (another of the source drain regions 36 ), and a body region 32 and located on a substrate that includes the handle substrate 10 and the buried insulator layer 20 . The planarization dielectric layer 60 overlies the semiconductor material portion. A second-type gate stack structure ( 51 , 58 ) is embedded in the planarization dielectric layer 60 and including a second-type gate dielectric 51 and a second-type gate electrode 58 that is embedded in the second-type gate dielectric 51 . The second-type gate dielectric 51 includes a horizontal portion 51 H 1 in contact with the body region 32 and a vertical portion having outer sidewalls that define a lateral extent of the second-type gate stack structure ( 51 , 58 ).
[0059] The second-type gate stack structure ( 51 , 58 ) includes a first portion P 1 contacting the semiconductor material portion and extending along a first horizontal direction (i.e., the lengthwise direction of the first-type gate stack structures ( 50 , 54 )) and a second portion P 2 extending along a second horizontal direction that is different from the first direction. The second horizontal direction may, or may not, be orthogonal to the first direction. In one embodiment, the second portion P 2 does not overlie the semiconductor material portion, and is laterally offset, i.e., is spaced, from the semiconductor material portion.
[0060] Each of the first-type and second-type gate dielectrics ( 50 , 51 ) can include a dielectric metal oxide having a dielectric constant greater than 8.0. The second-type gate dielectric 51 in the second portion P 2 can further include another horizontal portion 51 H 2 that is vertically offset relative to the horizontal portion 51 H 1 that contacts the body region 32 . In one embodiment, a bottom surface of the other horizontal portion 51 H 2 can be in contact with a horizontal surface of the planarization dielectric layer 60 that is located at a height between a topmost surface of the planarization dielectric layer 60 and a bottommost surface of the planarization dielectric layer 60 . In one embodiment, semiconductor material portion can be a semiconductor fin ( 32 , 36 , 36 ′) located on a buried insulator layer 20 in the substrate ( 10 , 20 ), and the bottom surface of the other horizontal portion 51 H 2 can be located in a horizontal plane located beneath a horizontal plane including a topmost surface of the semiconductor fin ( 32 , 36 , 36 ′). In another embodiment, semiconductor material portion is a semiconductor fin ( 32 , 36 , 36 ′) located on a buried insulator layer 20 in the substrate 910 , 20 ), and the bottom surface of the other horizontal portion 51 H 2 can be located in a horizontal plane located above a horizontal plane including a topmost surface of the semiconductor fin ( 32 , 36 , 36 ′).
[0061] Referring to FIGS. 9A , 9 B, and 9 C, a contact-level dielectric layer 80 can be deposited over the planarization dielectric layer 60 . Various contact via structures can be formed through the contact-level dielectric layer 80 . The various contact via structures can include, for example, gate contact via structures 85 that extend through the contact-level dielectric layer 80 and contact one of the gate electrodes ( 54 , 58 ), and active region contact via structures 86 that extend through a stack of the contact-level dielectric layer 80 and the planarization dielectric layer 60 and contact the source/drain regions 36 . Optionally, at least one metal semiconductor alloy portions (not shown) can be formed between the contact via structures ( 85 , 86 ) and the source/drain regions 36 or gate electrodes ( 54 , 58 ).
[0062] Referring to FIG. 10 , a second exemplary semiconductor structure can be derived from the first exemplary semiconductor structure by increasing the depth of the trench(es) 69 . In this case, a semiconductor material portion (e.g., one of the semiconductor fins ( 32 , 36 , 36 ′)) can be located on the buried insulator layer 20 , and a bottom surface of the other horizontal portion 51 H 2 of the second-type gate dielectric 51 can be in contact with a surface of the buried insulator layer 20 . In one embodiment, the bottom surface of the other horizontal portion 51 H 2 can be coplanar with a topmost surface of the buried insulator layer 20 .
[0063] Referring to FIG. 11 , a third exemplary semiconductor structure can be derived from the first exemplary semiconductor structure by increasing the depth of the trench(es) 69 . In this case, a semiconductor material portion (e.g., one of the semiconductor fins ( 32 , 36 , 36 ′)) can be located on the buried insulator layer 20 , and a bottom surface of the other horizontal portion 51 H 2 of the second-type gate dielectric 51 can be in contact with a surface of the buried insulator layer 20 . In one embodiment, the bottom surface of the other horizontal portion 51 H 2 can be located below a topmost surface of the buried insulator layer 20 .
[0064] While the disclosure has been described in terms of specific embodiments, it is evident in view of the foregoing description that numerous alternatives, modifications and variations will be apparent to those skilled in the art. Each of the various embodiments of the present disclosure can be implemented alone, or in combination with any other embodiments of the present disclosure unless expressly disclosed otherwise or otherwise impossible as would be known to one of ordinary skill in the art. Accordingly, the disclosure is intended to encompass all such alternatives, modifications and variations which fall within the scope and spirit of the disclosure and the following claims.
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A post-planarization recess etch process is employed in combination with a replacement gate scheme to enable formation of multi-directional wiring in gate electrode lines. After formation of disposable gate structures and a planarized dielectric layer, a trench extending between two disposable gate structures are formed by a combination of lithographic methods and an anisotropic etch. End portions of the trench overlap with the two disposable gate structures. After removal of the disposable gate structures, replacement gate structures are formed in gate cavities and the trench simultaneously. A contiguous gate level structure can be formed which include portions that extend along different horizontal directions.
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BACKGROUND AND SUMMARY OF THE INVENTION
This application claims priority from European Patent Application No. 05 010 419.9 filed May 13, 2005, hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The invention relates to a method for operating a sputter cathode with a target.
Material layers to be applied onto a substrate—for example a synthetic film or glass—are frequently applied by means of the so-called sputter process. This sputter process proceeds in a vacuum chamber in which is located a plasma.
In this process by means of the ions in the plasma, particles are knocked out of the target, which subsequently are deposited on a substrate opposite the target.
The target is connected to a cathode to which a negative voltage is applied, which accelerates positive ions from the plasma.
In order to knock the largest possible number of particles out of the target, employed in the proximity of this target are magnets whose magnetic field penetrates through the target. Hereby the electrons responsible for the ionization of the plasma are bunched in the proximity of the surface of the target. The combination of cathode and permanent magnet is also referred to as “magnetron”.
If cathode and target are planar, the magnetron is referred to as a planar magnetron.
However, for some time hollow cylindrical magnetrons are increasingly utilized due to their high target material yield. These magnetrons are sometimes also called tube cathodes.
On the outer side of a tubular cathode is located a target which is also tubular. The tubular target rotates about the longitudinal axis of the cathode, with magnets being stationarily disposed in the cathode. The magnetic field of these magnets penetrates cathode and target and consequently is also disposed in the plasma.
By “tube cathode” are often also understood entire units which comprise a motor, a rotary transmission leadthrough, bearings, electric sliders, cooling means lines and a magnet system, the magnet system together with a portion of the target cooling being disposed in the cylindrical target.
A sputter device with a magnetron cathode with rotating target is already known in which the target is cooled in a special way (DE 41 17 368 A1).
In another known rotating magnetron cathode on two opposing sites of the cathode magnets are provided such that two substrates can be provided simultaneously with a sputter coating (DE 41 26 236 A1).
Lastly, there is also known a rotating cathode for cathode sputtering, which supports a tubular structural part, capable of rotating about its axis, and on its circumference at least one material to be sputtered (EP 0 703 599 B1). This rotating cathode includes additionally a magnet system as well as mechanical means which during the sputtering make possible an oscillating rotary motion of the tubular structural part. This is intended to solve the problem involved in providing a method for the rapid exchange of the target material of a cathode for magnetron-assisted cathode sputtering. In order to attain uniform erosion in a configuration with two rotating different targets, each of which is developed in the form of a semicylinder, the rotating cathode during the deposition is allowed to oscillate at an amplitude which is less or equal to α/2. In the case of two different targets, it is α=180°.
The aim of the invention is eliminating the negative effect of the induction current on the coating quality in a sputter cathode with a target being moved through a magnetic field.
This aim is attained according to the present invention.
The invention consequently relates to a method for operating a magnetron sputter cathode, in particular a tube cathode or several tube cathodes forming an array. In such cathodes a target passes through a magnetic field whereby induction currents flow in the target distorting the magnetic field. This causes a nonuniform coating of a substrate. Thereby that the relative movement between magnetic field and target alternately reverses its direction, the effect of the magnetic field distortion can be compensated. This leads to greater uniformity of the coating on a substrate to be coated.
The advantage achieved with the invention comprises in particular that the deformations of the coating thickness distribution occurring in the case of a tube cathode or tube cathode configuration with conductive target material rotating continuously in one direction are avoided.
Embodiment examples of the invention are shown in the drawing and will be described in the following in further detail.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 several tube cathodes disposed in parallel in a sputter chamber;
FIG. 2 the coating thickness distribution on a substrate under a static operation of a sputter unit with several tube cathodes;
FIG. 3 the coating thickness distribution on a substrate under dynamic operation of a sputter unit with several cathodes, with the cathodes rotating in a first direction;
FIG. 4 the coating thickness distribution on a substrate under dynamic operation of a sputter unit with several cathodes, with the cathodes rotating in a second direction;
FIG. 5 cross section through a tube cathode;
FIG. 6 longitudinal section through a plasma chamber.
DETAILED DESCRIPTION
FIG. 1 shows a section through a vacuum chamber 1 , in which are located four rotatable tube cathodes 2 to 5 . Opposite to these tube cathodes 2 to 5 is disposed a substrate 6 to be coated, for example a glass panel.
Each of the tube cathodes 2 to 5 comprises a circular arc-shaped magnet yoke 7 to 10 as well as a bearing tube 11 to 14 , on whose outer side is disposed a cylindrical target 15 to 18 .
In the depiction of FIG. 1 , the tubes 11 to 14 with associated targets 15 to 18 rotate in the direction of arrows 19 to 22 , thus in the clockwise direction. However, they can also rotate in the counterclockwise direction.
In the circular arc-shaped magnet yokes 7 to 10 are disposed three permanent magnet series 23 to 34 , of which the permanent magnet series 23 , 25 ; 26 , 28 ; 29 , 31 and 32 , 34 have the same polarity, while the permanent magnet series 24 , 27 and 30 , 33 , respectively, located between them have the opposite polarity. The magnet yokes 7 to 10 with permanent magnet series 23 to 34 are disposed stationarily, i.e. the do not rotate with the tubes 11 to 14 and the targets 15 to 18 .
If the targets 15 to 18 are sputtered with a configuration according to FIG. 1 , on the surface of the substrate a coating is deposited which is comprised of the same material as the target. In the case of reactive sputtering the material sputtered off the target can additionally also enter into a chemical reaction and form a compound before it is deposited on the substrate. Since the tube cathodes 2 to 5 cannot be packed indefinitely closely, they have a spacing from one another which causes inhomogeneous coating perpendicularly to the longitudinal axes of the tube cathodes 2 to 5 projecting into the plane of drawing.
FIG. 2 shows the manner in which extends the resistance distribution of a metallic coating when the tube cathodes 2 to 5 do not rotate, i.e. if sputtering is carried out in the static state. The rotational axes of the tube cathodes 2 to 5 are oriented in the y-direction. This y-direction is the direction into the plane of drawing of FIG. 1 . The x-direction denotes the horizontal direction in FIG. 1 . The ellipses 40 to 43 denote the regions of high electric resistance, i.e. low coating thickness on the substrate. They are located directly beneath the individual tube cathodes 2 to 5 on the substrate. The main axes of the ellipses 40 to 43 , consequently, extend beneath the rotational axes of the tube cathodes 2 to 5 and denote regions of high electric resistance. Since directly beneath the tube cathodes the magnetic fields are weaker than in the margin regions of the tube cathodes, less sputter material is also deposited here. However, directly beneath the tube cathodes a lesser deposition of the target material occurs, which is reflected in a lesser coating thickness and therewith in an increased electric resistance. The ellipses 40 to 43 show the regions of increased electric resistance; in practice they are relatively narrow.
FIG. 3 shows the resistance distributions of the material sputtered onto the substrate 6 if all of the tube cathodes 2 to 5 rotate in the clockwise direction, thus in the direction of arrows 19 to 22 .
It can be seen that the distribution of the regions of increased resistance along the rotational axes of the individual tube cathodes 2 to 5 is no longer uniform, i.e. the ellipses become increasingly smaller with increasing x-distance. The observed effect of the length change of the ellipses also occurs in the case of single cathodes; however, it only becomes distinctly noticeable with cathode arrays with several cathodes. The mechanism for the increase of the shift of the region with less coating, and therewith high electric resistance in the y-direction, is not completely known. It is possible that through the overlapping plasma zones a disturbance is transmitted from cathode to cathode so that the effect is augmented.
FIG. 4 shows the distribution of the increased resistance in the case in which the tube cathodes 2 to 5 rotate counterclockwise. The distribution of increased resistance of the sputtered material on substrate 6 is also not uniform in this case, but it is in the reverse sense, i.e. the ellipses become continuously greater with increasing distance x.
It is evident that the asymmetries of the regions of low deposition during the rotation in the clockwise direction, on the one hand, and in the counterclockwise direction, on the other hand, are contradirectional. During the rotation in the clockwise direction ( FIG. 3 ) the main axes of the ellipses 44 to 47 become shorter in the x-direction, while the main axes of the ellipses 48 to 51 during rotation in the counterclockwise direction in the x-direction become longer.
If the tube cathodes 2 to 5 rotate for a time t 1 and at a specified rate in the clockwise direction and subsequently for the same time t 1 at the same rate in the counterclockwise direction, one obtains again the distribution depicted in FIG. 2 , i.e. the same distribution as in static sputtering. Two contradirectional errors are, so to speak, compensated. In order to obtain optimum uniformity of the coating on the substrate, however, it is not necessary for all cathodes to rotate always at precisely the same circumferential speed and in the same direction. Rather, the circumferential speeds and the durations of the revolution can vary. This applies especially if the individual cathodes have fabrication tolerances. In this case the circumferential speeds, etc. should be adapted to the particular cathodes.
The tube cathode 2 of FIG. 1 is once again depicted in FIG. 5 at an enlarged scale. In this representation are shown the field lines 60 , 61 of the magnetic field set up by the permanent magnets 23 to 25 .
It can be seen that the field lines extend symmetrically with respect to the tube cathode 11 and to the target 15 and that the magnetic field strength directly beneath the tube cathode is weaker than laterally to it.
This symmetric orientation of the field lines applies to static operation, i.e. if the tube cathode 2 does not rotate about the stationary permanent magnets 23 to 25 . However, if the tube cathode 2 does rotate about these permanent magnets 23 to 25 , the field lines of the permanent magnets 23 to 25 are intersected by the target 15 . The electrons located in an electrically conducting target are hereby subjected to forces perpendicular to the direction of motion of target 15 and to the direction of the field lines, i.e. perpendicularly to the plane of drawing. This causes a voltage U or an electric field strength E to occur in this direction in the target since the electrons are non-uniformly distributed along the longitudinal axis of target 15 . The electric field strength E can be calculated by means of the equation E i =v×B, if E i is the induced electric field strength, v the circumferential speed of the target and B the magnetic field strength of the permanent magnets 23 to 25 . Thereby an induced current results, which, in turn, sets up a magnetic field, which becomes superimposed on the present magnetic field of the permanent magnets 23 to 25 . The resulting magnetic field is hereby distorted, which causes the asymmetries depicted in FIGS. 3 and 4 .
The deformation of the coating thickness distribution occurs in the longitudinal direction of the cathode as well as also perpendicularly to it.
The magnetic fields shown in FIG. 5 are tilted off to one side through the superimposed magnetic fields, and specifically during rotation to the right into the one, and, in the case of rotation to the left, into the opposite direction. Through changes of equal length in the direction of rotation, the error occurring with the rotation in one direction can be compensated through the oppositely directed error, which occurs during rotation in the opposite direction. Accordingly, through defined time proportions of the direction of rotation, the distribution can be shifted specifically along the y-direction.
Through the currents induced in the target strong forces are also generated between the target and the permanent magnets 23 , 24 , 25 , which are opposite to the direction of rotation of the target. The effect described here in conjunction with rotating tube cathodes occurs correspondingly also during dynamic operation of planar cathodes, if between target and magnetic field a relative movement takes place.
FIG. 6 depicts a longitudinal section through the chamber 1 with the tube cathode 2 . The tube cathode 2 can be set into rotational motion by a drive located in a fitting 70 . In addition, at this fitting 70 are also provided a fluid inlet 71 and a fluid outlet 72 . Beneath the tube cathode 2 is located the substrate 6 to be coated. A gas inlet is denoted by 73 , located opposite of which is a (not shown) gas outlet on the opposing side of the vacuum chamber 1 .
The tube cathode 2 is connected to the negative pole of a voltage source 74 , here shown as a DC voltage source. The positive pole of the voltage source 74 is connected with the bottom 75 of the vacuum chamber 1 . A receptacle wall 76 separates the vacuum obtaining in the vacuum chamber 1 from the atmosphere encompassing the fitting 70 . In the fitting 70 is disposed a fluid pipe 77 , which encompasses the fluid inlet 71 and the fluid outlet 72 . Disposed coaxially about the fluid pipe 77 is a pipe 78 of an electrically nonconducting material. Between the two pipes 77 and 78 are disposed the sealing rings 79 , 80 , 81 and two arrangements of bearings 82 , 83 . In front of the arrangement of bearings 83 is a rotary driving unit 84 , which rotates the tube cathode 2 . At the other end of the tube cathode 2 rests a fitting 86 of this tube cathode 2 in a bearing 87 . By 88 , 89 are denoted the power supplies to which are connected the poles of the DC voltage source 74 .
Although FIG. 6 shows only one tube cathode, in the vacuum chamber 1 are located several tube cathodes perpendicularly to the plane of drawing. These tube cathodes can each be provided with their own driving unit. However, it is also possible to employ one driving unit for several tube cathodes.
In one embodiment the rotary driving unit 84 can be provided for rotation in the clockwise direction according to arrow 90 as well as for rotation in the counterclockwise direction according to arrow 91 .
The rotation of a tube cathode 11 in one direction is at least 360° in order for all areas of the target 15 to be utilized for sputtering. However, several rotations in the clockwise direction and subsequently the same number of rotations in the counterclockwise direction can be completed. However, the number of rotations in each direction must always be equal.
As a rule, the rotational speed or angular speed of the tube cathode is constant. However, in principle it is also possible to change the angular speed. The effect of the distortion of the magnetic field 60 , 61 is greater the higher the rotational speed.
If the tube cathode 11 is rotated n-times at a high speed in the clockwise direction, the resulting distortion error can be compensated at a low speed in the counterclockwise direction with m rotations, wherein m>n.
When using several tube cathodes, which form a so-called cathode array, the angular speeds can also vary from tube cathode to tube cathode.
In FIG. 6 a single cathode is connected to a DC voltage. However, it is also possible to utilize a small cathode pair, which involves two similar cathodes, connected to AC voltage. In this case the cathodes operate alternately as anode and as cathode.
The invention can also be utilized in cathode arrays for static coating. By static coating is understood a coating in which the substrate is at rest during the coating and does not move relative to the cathode. The magnet system can herein be either moved or not moved during the coating relative to the target.
All references cited herein are incorporated by reference in their entireties.
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The invention relates to a method for operating a magnetron sputter cathode, in particular a tube cathode or several tube cathodes forming an array. In such cathodes a target passes through a magnetic field, whereby induction currents flow in the target which distort the magnetic field. This results in the nonuniform coating of a substrate. By having the relative movement between magnetic field and target alternately reverse its direction, the effect of the magnetic field distortion can be compensated. This yields greater uniformity of the coating on a substrate to be coated.
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TECHNICAL FIELD
The present invention relates to a method for controlling a device for transporting hydrocarbons, in the form of a mixture of liquid and gas, between off-shore hydrocarbons production means and a unit for processing the said hydrocarbons.
STATE OF THE PRIOR ART
A conventional technique used for exploiting subsea deposits of hydrocarbons consists in pooling the hydrocarbons produced in liquid and gaseous form by several neighbouring wells and transporting them to a processing plant mounted on a floating support or on a support of the platform type, above sea level.
For this purpose, the underwater wellheads with which the production wells are equipped are connected to a single transport pipe which runs along the seabed between the wellheads and the support leg of the treatment plant and then rises, via a riser system, to above sea level, where it is connected, usually through an outlet choke, to the treatment plant.
Under certain operating conditions, the mixture of liquid and gas in the transport pipe is in the form of an alternating series of plugs of liquid and pockets of gas which result in substantial fluctuations in the pressures and flowrates of the two fluids, which fluctuations are incompatible with correct operation of the treatment plant and also disrupt the flow of hydrocarbons in the wells.
One method which aims to avoid the development of plugs of liquid in such a hydrocarbons transport device is described in document EP 0,410,552 A 2 of 30.01.91.
As the outlet choke is used as a means of controlling the flows of gas and of liquid in a downstream section of the transport pipe, this method consists in:
determining a flow of fluid, which is defined as the sum of the flows of gas and of liquid in the said section, and
adjusting the flow-control means so as to minimize the variations in flow of fluids in the said section.
According to this method, the flows of fluid are defined as being the instantaneous volumetric flowrates of the fluids.
This method is not suited to the control of a hydrocarbons transport device which comprises, in addition to the transport pipe, means of injecting gas upstream of the rising section of the said pipe, which allow gas to be injected in order to lighten the mixture of liquid and gas produced so as to make it easier to raise to the surface, because, in this case, the measurement of the flow of gas produced is rendered inaccurate by the flowrate of injected gas.
Furthermore, this method does not allow the transport device to be started up gradually with a minimum of pressure and flowrate surges, nor does it allow the device to be controlled during disrupted particular operations such as the passage of a scraping device, nor does it, in all phases of operation, prevent the formation of plugs of gas in the transport pipe accompanied by plugs of liquid hydrocarbons.
Nor can it be used for producing hydrocarbons at low cost at an established rate, that is to say by injecting a minimum amount of gas for a given amount of hydrocarbons produced.
DESCRIPTION OF INVENTION
The present invention is intended precisely to overcome these drawbacks by proposing a method for controlling a device for transporting hydrocarbons between production means and a treatment plant which makes it possible to prevent the formation of plugs and ensure the stability of the flowrate of hydrocarbons in disrupted situations, thus creating conditions that are favourable to the optimum control of the treatment plant.
Furthermore, by virtue of the invention, a maximum amount of produced hydrocarbons can be transported at the best cost.
To this end, the invention proposes a method for controlling a device for transporting liquid and gaseous hydrocarbons between production means and a treatment plant, which device comprises a pipe, for transporting the hydrocarbons, which has a lower section connected to the hydrocarbon production means and an upper end connected to the treatment plant through an adjustable-aperture outlet choke, the said method being characterized in that the said device additionally comprises a gas-injection pipe which has an upstream end connected to a source of pressurized gas through a control valve and a downstream end connected to the lower section of the hydrocarbons transport pipe and in that, when the outlet choke and the control valve are closed, it includes a start-up phase which consists in performing the following sequence of steps:
a step of initiating the transport of hydrocarbons which consists:
in comparing the pressure in the lower section of the hydrocarbons transport pipe with a predetermined threshold Pf1 and:
a) if this pressure is above the threshold Pf1, in gradually opening the outlet choke to a predetermined value to ensure that the hydrocarbons transported flow at a predetermined minimum flowrate, or
b) if this pressure is below the threshold Pf1, in injecting gas at a predetermined flowrate to encourage the hydrocarbons to flow through the transport pipe, and, when the difference between the pressures upstream and downstream of the outlet choke exceeds a predetermined threshold, in gradually opening the said choke ( 9 ) to a predetermined value to ensure that the hydrocarbons transported flow at a predetermined minimum flowrate,
in waiting for a predetermined length of time to allow the minimum hydrocarbon flowrate to become established;
a step of ramping up to transport speed, which consists in periodically performing the following operations:
determining a pressure instability factor F in the lower section of the pipe, and comparing the instability factor F with two predetermined thresholds F1 and F2, F2 being higher than F1, and:
a) if the instability factor F is below F1 and if a target transported-hydrocarbons flowrate has not been achieved, opening the outlet choke wider by a predetermined amount,
b) if the instability factor F is below F1 and if a target transported-hydrocarbons flowrate has been achieved, decreasing the flowrate of injected gas by a predetermined amount,
c) if the instability factor F is between F1 and F2 and if the injected-gas flowrate is zero, injecting a predetermined flow of gas to fill the gas-injection pipe as far as its downstream end,
d) if the instability factor F is above F2, increasing the gas flowrate by a predetermined amount to ensure that there is a continuous flow of gas in the lower section of the pipe and so as to increase the pressure difference available across the outlet choke,
repeating the above operations if at least one of the previous actions have been performed within a predetermined space of time.
According to another feature of the invention, the start-up phase is followed by a production phase which consists in ensuring production stability by performing the following monitoring operations:
determining at least one factor G which characterizes the start of an interruption in the circulation of the gaseous hydrocarbons in the lower section of the pipe,
comparing the said factor G with a predetermined threshold and:
if it exceeds the threshold, increasing the gas flowrate to a predetermined value and reducing the aperture of the outlet choke to a predetermined value,
otherwise, comparing the flowrate of the hydrocarbons produced with the target flowrate, and:
a) if it is below the target flowrate, increasing the flowrate of injected gas,
b) if it is above the target flowrate, decreasing the flowrate of injected gas,
if an action has been taken during the preceding monitoring operations, the production phase then consists in periodically performing the following stability-control operations:
determining a pressure instability factor S in the lower section of the pipe, and
comparing the instability factor S with two predetermined thresholds S1 and S2, S2 being higher than S1, and:
a) if the instability factor S is below S1 and if a target transported-hydrocarbons flowrate has not been achieved, opening the outlet choke wider by a predetermined amount,
b) if the instability factor S is below S1 and if a target transported-hydrocarbons flowrate has been achieved, decreasing the flowrate of injected gas by a predetermined amount,
c) if the instability factor S is above S2, increasing the injected-gas flowrate by a predetermined amount to ensure that there is a continuous flow of gas in the lower section of the pipe and so as to increase the pressure difference available across the outlet choke, repeating the above operations if at least one of the previous actions have been performed within a predetermined space of time, resuming the previous monitoring operations.
According to another feature of the invention, the instability factor S is calculated from the difference between the pressure in the lower section of the pipe and the pressure upstream of the outlet choke.
According to another feature of the invention, the instability factor F is calculated from the pressure in the lower section of the pipe.
According to another feature of the invention, with the means of producing hydrocarbons comprising an outlet to which the lower section of the hydrocarbons transport pipe is connected, the instability factor F is calculated from the difference between the pressure in the lower section of the pipe and the pressure at the outlet from the hydrocarbons production means.
According to another feature of the invention, the factor G which characterizes the start of an interruption in the flow of gaseous hydrocarbons in the lower section of the pipe is calculated from the pressure in the lower section of the pipe.
According to another feature of the invention, with the hydrocarbons production means comprising an outlet to which the lower section of the hydrocarbons transport pipe is connected, the factor G which characterizes the start of an interruption in the flow of the gaseous hydrocarbons in the lower section of the pipe is calculated from the difference between the pressure in the lower section of the pipe and the pressure at outlet from the hydrocarbons production means.
According to another feature of the invention, the pressure in the lower section of the hydrocarbons transport pipe is measured using a sensor.
According to another feature of the invention, the method consists in:
preceding the step of initiating the transport of hydrocarbons with a preliminary step which consists in opening the valve which controls the flowrate of injected gas, so as to obtain an injected-gas flowrate Q1 for a predetermined length of time,
permanently maintaining the injected-gas flowrate at a value at least equal to Q1,
calculating the pressure in the lower section of the hydrocarbons transport pipe from the pressure downstream of the control valve and from the injected-gas flowrate.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood from reading the following description which is given by way of example, with reference to the appended drawings in which the single figure depicts a device for transporting hydrocarbons between subsea oil wells and a treatment plant, allowing the invention to be implemented.
DETAILED DESCRIPTION OF THE INVENTION
In general, the method of the invention is used to control a device for transporting hydrocarbons between means of producing the said hydrocarbons and a unit for processing them.
The single figure depicts an offshore installation for producing hydrocarbons in the form of a mixture of liquid and gas, which comprises:
production means 1 for producing from two wells 2 and 3 , the production of which is combined in a manifold 4 which has an outlet 5 for the hydrocarbons produced,
a unit 10 for processing the hydrocarbons produced,
a source 11 of pressurized gas,
a pipe 6 for transporting the hydrocarbons produced, with a lower section 7 , and an upper end 8 , equipped with an outlet choke 9 ,
a gas-injection pipe 16 , fitted with a control valve 15 , which has an upstream end 12 and a downstream end 17 ,
a sensor 13 for measuring the flowrate of injected gas and which delivers an electronic signal which represents this flowrate,
a sensor 14 for measuring the pressure upstream of the choke 9 , which delivers an electronic signal which represents this pressure,
a sensor 23 for measuring the pressure downstream of the control valve 15 , which delivers an electronic signal which represents this pressure,
a sensor 24 for measuring the pressure in the lower section 7 of pipe 6 , which delivers an electronic signal which represents this pressure,
a programmable controller 18 with inputs which 30 receive the electronic signals delivered by the sensors 13 , 14 , 21 , 23 and 24 and outputs which deliver signals for operating the outlet choke 9 and the control valve 15 ,
means 22 for dialogue between operator and controller 18 .
The pipe 6 for transporting the hydrocarbons produced connects the outlet 5 of the hydrocarbons production means to the treatment plant 10 through the outlet choke 9 placed at the upper end 8 of the pipe 6 .
The pipe 6 runs along the seabed 19 for a distance L, the depth of water being H; the treatment plant 10 and the source 11 of pressurized gas, the valve 15 , the choke 9 and the controller 18 are located above sea level 20 .
The controller 18 additionally comprises, and this is not depicted in the single figure, a memory which has been loaded beforehand with a control program and with the data needed to control the hydrocarbons transport device, particularly with all the predetermined values of the adjustment variables. This data is entered in advance by an operator using operator/controller dialogue means 22 and can be updated by the same means during production.
Some of this data may be entered by a control-assistance computer, not depicted in the single figure.
The controller 18 automatically controls the flowrate of injected gas measured by means of the sensor 13 , to keep it at a set point value which is determined according to the control program and the values of the adjustment variables and as a function of the signals delivered by the sensors 14 , 21 and 23 , by acting on the control valve 15 .
Before the hydrocarbons transfer device is put into operation, the outlet choke 9 and the control valve 15 are closed.
The method of the invention comprises a phase of starting up the transport device, during which phase the controller 18 opens the control valve 15 to inject a flowrate Q1 of gas for an experimentally-determined length of time so that the pipe 16 no longer contains liquid hydrocarbons. The value of Q1 is determined as a function of the characteristics of the installation and may be set, for example, at 1% of the maximum gas-injection flowrate for which the installation has been designed so that pressure drops due to friction are negligible.
On the basis of the value of the pressure Pa downstream of the control valve 15 , measured by the sensor 23 , the controller 18 calculates the pressure Pf in the lower section 7 of the pipe 6 , using the following formula:
Pf=Pa(1+K)
in which K is a constant such that K·Pa represents the weight of a column of gas of unit cross section, of height H under the thermodynamic conditions in the pipe 16 .
The injected-gas flowrate will be kept at a value at least equal to Q1 throughout the following operations.
The start-up phase then comprises a step of initiating the transport of hydrocarbons, during which step the controller 18 performs the following operations:
it compares the pressure Pf with a threshold Pf1 which has been predetermined as a function of the height H of water column and of the physical characteristics of the hydrocarbons transported so that the exceeding of this threshold signifies that there is sufficient pressure margin to allow production to start without the need to supply external energy,
if this pressure Pf is higher than Pf1, then the controller 18 issues a command to gradually open the outlet choke 9 to a predetermined value to ensure that the hydrocarbons flow at a minimum flowrate Qm set experimentally, for example, to be between 20 and 50% of the maximum flowrate for which the transport device was designed,
if this pressure Pf is lower than Pf1, this means that the pressure Pf is not high enough to give the outlet choke 9 sufficient control margin, and in such a case the controller 18 issues a command to increase the injected-gas flowrate to a flowrate Qd which is predetermined by calculation, to encourage the transported hydrocarbons to flow.
When the difference between the pressures upstream and downstream of the choke 9 , measured by the sensors 14 and 21 , respectively, exceeds a threshold that has been predetermined by calculation, the controller 18 issues a command to gradually open the choke 9 to a predetermined value so that the hydrocarbons transported achieve the minimum flowrate Qm.
The controller 18 waits for a length of time that has been predetermined by calculating the time required for a sweep through the pipe 6 , to ensure that the minimum flowrate Qm for transported hydrocarbons becomes established.
The start-up phase then comprises a step of ramping up to transport speed, during which step the controller 18 determines an instability factor F for the pressure Pf in the lower section 7 of the pipe 6 , using the following formula:
F=(Pfmax−Pfmin)/Pfmean
in which:
Pfmax represents the maximum value of the pressure Pf over a sliding 5-minute period,
Pfmin represents the minimum value of the pressure Pf over a sliding 5-minute period,
Pfmean represents the temporal mean value of the pressure Pf over a sliding 5-minute period.
The controller 18 compares F with two thresholds F1 and F2 which have been predetermined by calculating characteristic fluctuations of an acceptably stable flow, F2 being higher than F1.
If F is lower than F1, which is equal, for example, to 50%, and if the flowrate of transported hydrocarbons, estimated from the aperture of the choke 9 and from the difference in pressures measured by the sensors 14 and 21 , is lower than a target production flowrate set by an operator, the controller 18 increases the aperture of the outlet choke 9 by a predetermined amount, for example 2% of the maximum aperture.
If F is lower than F1 and if the transported-hydrocarbons target flowrate is achieved, then the controller 18 reduces the injected-gas flowrate by reducing the value of the set point to which the said flowrate is slaved.
If F is higher than F2, which is equal, for example, to 75%, the controller 18 issues a command to increase the injected-gas flowrate to a value Qd so as:
to ensure a flow of gas injected into the lower section 7 of the pipe 6 ,
to increase the pressure difference available across the outlet choke 9 in order to maintain a margin for controlling the flowrate,
to prevent the formation of a plug of liquid by continuous and forced injection of gas to ensure that there is a liquid-gas mixture present in the rising part of the pipe 6 , even if there is no gas in the hydrocarbons entering the section 7 , and
to allow the well to continue to produce.
If one of the previous four actions have been performed during a minimum stabilization period, the length of which is predetermined by calculation and is for example 60 minutes, the operations in the step of ramping up the transport speed are repeated.
These actions are thus repeated periodically according to the value of F with respect to the thresholds.
If it has not been possible to satisfy any of the conditions which initiate an action during the minimum stabilization period, then the start-up phase is complete.
As the start-up phase is complete, the transported-hydrocarbons flowrate is equal to the target flowrate. According to the invention, this start-up phase is followed by a production phase during which the controller 18 monitors the stability of production by performing the following operations:
It determines a factor G which characterizes the start of an interruption in the flow of gaseous hydrocarbons in the lower section 7 of the pipe 6 , by applying the following formula:
G=[(Pfmax2−Pfmin2)(Pfmean2−Pfmean30)]/[(Pfmax30−Pfmin30)·Pfmean30]
In which:
Pfmean2, Pfmax2 and Pfmin2 respectively represent the sliding mean, the maximum value and the minimum value, over the last two minutes, of the pressure in the lower section of the transport pipe,
Pfmean30, Pfmax30 and Pfmin30 respectively represent the sliding mean, the maximum value and the minimum value, over the last 30 minutes, of the pressure in the lower section of the transport pipe.
The controller 18 compares the calculated value of factor G with a predetermined start-of-stabilization threshold SD.
If this value G exceeds the predetermined threshold SD, which is equal, for example, to 50%, the controller 18 issues a command to increase the injected-gas flowrate to a value which is predetermined by calculation and equal, for example, to 90% of the flowrate for which the installation was designed, and issues a command to close the outlet choke 9 as far as a value which has been predetermined by calculation.
If G does not exceed the threshold SD, the controller 18 compares the flowrate of produced hydrocarbons, estimated from the pressures upstream and downstream of the choke 9 and from the hydraulic characteristics of the said choke, with the target flowrate.
If the produced-hydrocarbons flowrate is lower than the target flowrate then the controller 18 issues a command to increase the injected-gas flowrate by a predetermined increment, for example 5% of the maximum value of the injected-gas flowrate for which the transport device was designed.
If the produced-hydrocarbons flowrate is higher than the target objective, then the controller 18 issues a command to reduce the injected-gas flowrate by a predetermined decrement, for example 5% of the maximum value of the injected-gas flowrate for which the transport device was designed.
If, during the previous monitoring operations, an action has been needed, the controller 18 determines a factor S representative of the instability of the pressure in the lower section 7 of the pipe 6 , for example the ratio between the effective weight of the column of fluid in the rising part of the pipe 6 and the theoretical weight of this column. This ratio is calculated using the following formula: S = Pfmean5 - Pupstream - K λ Pr m × Pr m + Kz ( Kg + Qg / Qp ) Kd + Kz ( Kg + Qg / Qp )
In which:
Pfmean5 represents the sliding mean, over the last 5 minutes, of the pressure in the lower section of the transport pipe,
Pupstream5 represents the sliding mean, over the last 5 minutes, of the pressure upstream of the choke 9 ,
Kλ is a constant to take account of the frictional pressure drop in the rising part of the pipe 6 ,
Kz is the constant relating to the compressibility of the gas and to its weight,
Kg is a constant relating to the amount of gas associated with the liquids produced,
Kd is a constant relating to the density of the liquids produced,
Qg is the sliding mean, over the last 5 minutes, of the injected-gas flowrate,
Qp is the sliding mean, over the last 5 minutes, of the flowrate of liquid hydrocarbons transported,
Prm is the mean pressure in the rising part of the pipe 6 , calculated using the formula Prm=(Pfmean5+Pupstream5)×½.
The flowrate Qg is measured using the sensor 13 and Qp is estimated from the pressures upstream and downstream of the choke 9 and from the hydraulic characteristics of the said choke.
Furthermore, S=200 if the instantaneous pressure Pf in the lower section 17 of the pipe 6 increases by more than 10% during the sliding 5-minute period and S=0% if the instantaneous pressure Pf in the lower section 17 of the pipe 6 decreases by more than 10% during the sliding 5-minute period.
If the factor S which reflects the instability in the pressure in the lower section of the pipe 6 is below the predetermined threshold S1, which is equal, for example, to 90%, and if the transported-hydrocarbons target flowrate is achieved, then the controller 18 issues a command to reduce the gas flowrate by a predetermined amount, for example 5% of the maximum value of the hydrocarbons flowrate for which the transport device was designed.
If the factor S which reflects the instability in the pressure in the lower section of the pipe 6 is above a predetermined threshold S2, which is equal, for example, to 150%, then the controller 18 issues a command to increase the injected-gas flowrate by a predetermined amount equal, for example, to 20% of the maximum flowrate for which the installation was designed, to ensure that there will be a continuous flow of gas in the lower section of the pipe 6 and to increase the pressure difference available across the outlet choke.
If at least one of the actions resulting from the previous stability control exercise has been performed within a predetermined length of time equal, for example, to 60 minutes, the controller 18 repeats the previous stability control operations.
If not, the controller 18 resumes the previous monitoring operations.
By virtue of the method of the invention, for a given target production of hydrocarbons, the amount of gas injected is minimal and the stability of the flows and of the pressure in the lower section 7 of the pipe 6 is ensured.
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The invention relates to a method for controlling a device for transporting hydrocarbons in the form of a mixture of liquid and gas between production means ( 1 ) and a treatment plant ( 10 ).
The method according to the invention for controlling a device comprising a hydrocarbons transport pipe ( 6 ) fitted with an adjustable-aperture outlet choke ( 9 ) to which a gas-injection pipe ( 16 ) fitted with a control valve ( 15 ) is connected, is characterized in that it includes a start-up phase which consists in performing the following sequence of steps:
a step of initiating the transport of hydrocarbons,
a step of ramping up to transport speed, then a production phase, during which phases the outlet choke ( 9 ) and the control valve ( 15 ) are operated in such a way as to maintain the stability of the pressure in the pipe ( 6 ) for transporting the hydrocarbons produced.
The invention finds an application in the operation of off-shore oil production installations.
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TECHNICAL FIELD OF THE INVENTION
The present invention pertains in general to paper and card stock folding machines, and more particularly, to folding machines forming pocketed card stock or paper members having a wide peripheral edge.
BACKGROUND OF THE INVENTION
The printing and publishing industry has long used folding machines to fold paper stock into many different configurations. Folding machines have conventionally been used to fold everything from leaflets and sheets of regular paper to card stock. Folding machines have also been used to form pocketed folders; however, these pocketed folders had substantially no width to their pockets. The pocket was formed by a single fold. These general purpose paper folding machines typically employed a first roller assembly which included many folding rollers which operated in conjunction with fold pans supported on a parallel fold pan rail at differing levels adjacent to the folding rollers. Paper or card stock passed through a set of rollers would travel through the roller pair and engage the fold pan, whereupon the stock buckled and returned through a folding roller pair.
The prior art flat pocketed folders could be used to hold a few sheets of paper, but could not be used to hold a large number of papers or anything thicker than a few pieces of paper. To form a pocketed folder with a wide edge, using two folds, such that a large number of papers or something larger than a few pieces of paper could be put in the folder, the folders had to be formed by hand. These wide edged, pocketed card stock or paper folders could range through any size and could even take the form of a small box. The main problem was that manufacturing was time consuming since it was done by hand.
SUMMARY OF THE INVENTION
The present invention disclosed and claimed herein comprises a device and method for forming a pocketed card stock or paper member having a wide peripheral edge. A template is provided having a forming edge with a shape corresponding to the wide peripheral edge of the member. A flexible sheet of card stock or paper is also provided. An urging device is provided for urging the flexible sheet of card stock or paper adjacent to the template such that an extended portion thereof extends beyond the forming edge of the template and a remaining portion thereof does not extend beyond the forming edge of the template. A folding device is provided for urging the extended portion around the forming edge and a securing device is provided for securing the extended portion to the remaining portion of the flexible sheet of card stock or paper after the extended portion has been urged around the forming edge to form a wide edge. The flexible sheet of card stock or paper is held in contact with the template with vacuum pressure. The folding device comprises a roller or a spring loaded bar to force the wide edge of the flexible sheet around the template to form two creases in the flexible sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying Drawings in which: FIG. 1 illustrates a perspective view of the system of the present invention; FIG. 1a illustrates a bottom view of one section of the template; FIG. 1b illustrates a top view of one section of the template; FIG. 1c illustrates a cross-sectional view of one section of the template; FIG. 1d illustrates a top view of both sections of the template; FIG. 2a represents a top view of the flexible sheet of card stock or paper; FIG. 2b represents a side elevational view of the card stock or paper supply bin in the template; FIG. 3 represents a perspective view of the ramp and the folding plow; FIG. 3a represents a top view of the ramp and the folding plow; FIG. 4 illustrates a side elevational view of the tape application mechanism; FIG. 5a illustrates a side elevational view of the tape application operation; FIG. 5b illustrates a side view of the tape application operation after the breaking of the tape; FIG. 6 illustrates a side view of the roller after folding the first crease of the wide edge and while folding the second crease of the wide edge; FIGS. 7a-7e illustrate side elevational views of the sequence of folding the wide edge with a roller; FIG. 8 illustrates a perspective view of the finished pocketed card stock or paper member; FIGS. 9a-9e illustrates a side view of the sequence of folding the wide edge with a tensioned bar; FIG. 10 illustrates a schematic representation of the control system of the present invention; and FIG. 11 illustrates a flowchart of the system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, there is illustrated a perspective view of the system of the present invention. A two-piece template 12 is provided. A piece of card stock or paper 14 with an extended portion is provided and is placed into contact with the template. The piece of card stock or paper 14 has tabs 16 extending from its side. The template is attached to a carriage 17 which is driven by a chain or a belt drive 18 to move the template 12 down the device. Two ramps 20 are provided to fold the tabs at a 90° angle such that they are perpendicular to the piece of card stock or paper 14. Two plows 22 are provided to fold the tabs 16 around the template 12 at another 90° angle such that they are parallel to the piece of card stock or paper 14. An adhesive mechanism 24 is provided to place adhesive on the folded tabs 16. Even though adhesive refers to tape in the preferred embodiment, it should be noted that adhesive includes glue, as well as tape. A folding roller 26 is provided to crease the extended portion of the card stock or paper 14 around the template 12 such that a wide edge is formed. The folding roller 26 also presses the extended portion of the paper or card stock 14 into contact with the tabs 16, which have been folded and have had adhesive applied to them.
Referring now to FIG. 1a, there is illustrated a view of the underside of one section of the template 12. Channels 32 are provided on the underside of the template 12. The channels 32 are connected by an enclosed inner chamber 34 to a hose 36 which is connected to a vacuum pressure.
Referring now to FIG. 1b, there is illustrated a view of the top side of one portion of the template 12. A channel 40 is provided in the corner of the template corresponding to the position of the folded card stock or paper tab 16. The channel 40 is connected by an enclosed inner chamber 42 to a vacuum hose 44.
Referring now to FIG. 1c, there is illustrated a cross-sectional view of one portion of the template 12. The bottom channels 32 are shown, as is one of the enclosed inner chambers 42.
Referring now to FIG. 1d, there is illustrated a top view of a full template 12 with the two portions connected together. There is shown a connecting bracket 50 and the two inner chambers 42, as well as the top channels 40. The vacuum hoses 36 and 44 are also shown.
Referring now to FIG. 2a, there is illustrated a top view of an example of a flexible sheet of card stock or paper 14 used in the present invention. The flexible sheet of card stock or paper 14 has two extended portions 54, which extend beyond a first fold score 56 and a second fold score 58. The flexible sheet of card stock or paper 14 also has two card stock or paper tabs 16 extending therefrom. These card stock or paper tabs 16 contain a first fold score 60 and a second fold score 64.
Referring now to FIG. 2b, there is illustrated a side elevational view of a card stock or paper supply bin 62, the flexible sheet of card stock or paper 14 and the template 12. The supply bin 62 contains numerous sheets of flexible sheets of card stock or paper 14. The supply bin 62 containing the flexible sheets of card stock or paper 14 is placed directly beneath the template 12.
In operation, the supply bin 62 moves upward until the template 12 is in contact with the uppermost flexible sheet of card stock or paper 14. At this time, a vacuum pressure source (not shown) is turned on and connected to the vacuum hose 36 and air is vacuumed out of the inner chamber 34 and the channels 32 such that the flexible sheet of card stock or paper 14 remains attached to the template 12. The edges of the template 12 correspond to the first fold scores 60 and the first fold score 56 of the extended portion 54 of the flexible sheet of card stock or paper 14. After the sheet of card stock or paper 14 is attached to the template 12, the supply bin 62 lowers such that it is out of the way of the carriage 17. The carriage 17, which supports the template 12, is then moved by the chain or belt drive 18.
Referring now to FIG. 3, there is illustrated a perspective view of the ramp 20 and plow 22. The ramp 20 extends beyond the plow 22 and the plow 22 extends across the top portion of the ramp 20.
Referring now to FIG. 3a, there is illustrated a top view of the ramp 20 and the folding plow 22 in operation. The flexible sheet of card stock or paper 14, having card stock or paper tabs 16, is propelled by the template 12 into contact with the ramp 20. When this occurs, the card stock or paper tab 16 is lifted up and folded at a 90° angle along its first fold score 60. Then, as the tab 16 continues past the ramp, it comes in contact with the plow 22 which folds the tab 16 again at a 90° angle along its second fold score 64 onto the top of the template 12. When this occurs, negative air pressure is applied to vacuum hose 44 and inner chamber 42 such that there is a vacuum in the channel 40. This holds the folded tab 16 in place.
Referring now to FIG. 4, there is illustrated a side elevational view of the adhesive application mechanism 24. A roll of tape 70 that has adhesive 80 on both sides of the tape is provided. Idler rollers 72 are also provided. A depression roller 74 is provided for coming into contact with the tabs. A venturi 76 is provided to take up the backing from the spent tape. In operation, when the card stock or paper tab 16 is directly beneath the depression roller 74, the adhesive mechanism 24 via a pneumatic piston member 77 is lowered such that the depression roller 74 is in contact with the card stock or paper tab 16, as shown in FIG. 5a. As the tab 16 moves past the depression roller 74, it pulls the tape adhesive 80 along with it. After coming into contact with the card stock or paper tab 16, the tape backing 78 is pulled away from the tape adhesive 80 and the tape adhesive 80 is left attached to the card stock or paper tab 16 due to the fact that the tape adhesive 80 adheres better to the card stock or paper than to the tape backing 78. The remaining tape backing 78, after passing through two idler rollers 72, is extracted by a venturi 76. Once the end of the card stock or paper tab 16 is directly under the depression roller 74, the roll of tape 70 is stopped from turning and the whole adhesive application mechanism 24 moves upward, thereby breaking the adhesive of the tape 80, as shown in FIG. 5b.
Referring now to FIG. 6, there is illustrated a side view of the folding roller 26 folding the extended portions 54 of the sheet of card stock or paper 14. A blast of air pushes the extended portion 54 above the plane of the roller 26. A template 12 carries the card stock or paper sheet 14 into contact with the folding roller 26. The roller 26 makes a first fold along the first fold score 56 and then a second fold along the second score 58. These folds are made up against the template 12. After the two folds are completed, the roller 26 continues along the extended portion 54 and presses the extended portion 54 against the tape adhesive 80, which has been deposited along the tab 16.
Referring now to FIGS. 7a-7e, there are illustrated sequential views of the operation of the folding roller 26. As the template 12 moves itself and the flexible sheet of card stock or paper 14 toward the folding roller 26, in FIG. 7a, the folding roller 26 is placed below the plane of the flexible sheet of card stock or paper 14 in the extended portion 54. When the folding roller 26 comes into contact with the extended portion 54, it begins to make the first fold along a first fold score 56, as in FIG. 7b. In FIG. 7c, the first fold has been completed and as the template 12 moves forward, the folding roller 26 moves upward and in FIG. 7d begins to make the second fold along the second fold score 58. After completing the second fold in FIG. 7e, the folding roller 26 moves along the extended portion 54 and presses it against the folded tab 16 and the two are then adhered together.
Referring now to FIG. 8, there is illustrated a perspective view of a completed pocketed card stock or paper member 14. The extended portion 54 is shown after being folded along the first fold score 56 and the second fold score 58. The extended tab 16 is shown after being folded first on its first fold score 60 and again on its second fold score 64. The extended portion 54 has been secured to the folded portion of the extended tab 16 by tape adhesive 80. The pocket has a width 82.
Referring now to FIGS. 9a-9e, there is shown a side view of an alternate folding operation utilizing a tension bar 86. In FIG. 9a, there is shown the tension bar 86, the extended portion 54 of the sheet of card stock or paper 14, the folded tab 16, the template 12 and the flexible sheet of card stock or paper 14. As the template 12 moves itself and the flexible sheet of card stock or paper 14 toward the tension bar 86, in FIG. 9a, the tension bar 86 is placed below the plane of the flexible sheet of card stock or paper 14 in the extended portion 54. When the tension bar 86 comes into contact with the extended portion 54, it begins to make the first fold along a first fold score 56, as in FIG. 9b. In FIG. 9c, the first fold has been completed and, as the template 12 moves forward, the tension bar 86 moves upward and, as illustrated in FIG. 9d, begins to make the second fold along the second fold score 58. After completing the second fold, as illustrated in FIG. 9e, the tension bar 86 moves along the extended portion 54 and presses it against the folded tab 16 and the two are then adhered together.
Referring now to FIG. 10, there is illustrated a schematic diagram of the control system of the present invention. A processor 90 is provided with an input device 92 interfaced thereto. Also connected to the processor 90 is a supply bin drive 94, a motor 96 for the chain or belt drive 18, a vacuum source 98 to provide vacuum, various sensors 100, the driver for the adhesive mechanism 102, a brake for the adhesive mechanism 104 and a valve 106 to release a blast of air from a pressurized air source (not shown).
Referring now to FIG. 11, there is illustrated a flowchart of the operation of the present invention. After a start command is received from the input device 92, the processor 90 causes the supply bin drive 94 to lift the paper bin 62 such that the card stock or paper 14 contacts the template, as indicated in an operation block 116. After this happens, a sensor input 100 instructs the processor 90 to turn on the vacuum source 98 to the bottom of the template 12, as indicated by an operation block 118. After the vacuum source 98 has been turned on, the processor 90 instructs the supply bin drive 94 to lower the supply bin 62, as indicated by an operation block 120. Next, the processor 90 instructs the drive motor 96 to move the template 12 forward, as indicated by an operation block 122. As this happens, the processor 90 turns on a second vacuum 98 to cause vacuum pressure to be created for the top channels of the template 40, as in block 124. As this happens, the drive motor 94 continues to move the template 12 forward such that the tabs 16 come into contact with the ramp 20 and the folding plow 22 and are folded onto the top of the template 12 and held in place by the vacuum pressure, as indicated by an operation block 126. When the tabs 16 are located directly under the depression roller 74 of the adhesive application mechanism 24, sensors 100 instruct the processor 90 to control the adhesive drive 102 to lower the adhesive application mechanism 24 and, when the sensors 100 indicate that the end of the tabs 16 are moving out from under the depression roller 74, the processor 90 instructs the tape brake 104 to stop the roll of tape 70, as indicated by the operation block 128. Then, as the sensors 100 sense that the extended portion 54 is nearing the folding roller 26, the processor 90 causes an air blast 106 to push the extended portion 54 upward, as indicated in operation block 130. Next, as the extended portion 54 is moved into contact with the folding roller 26, the extended portion 54 is folded over the template 12 into contact with the tabs 16, as indicated in operation block 132. After the extended portion 54 is folded over into contact with the tabs 16, the program proceeds to an end block 134.
Although the preferred embodiment has been described in detail, it should be understood that various changes, substitutions and alterations can be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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A device and method for forming a pocketed card stock or paper member having a wide peripheral edge. A template (12) is provided having a forming edge with a shape corresponding to the wide peripheral edge of the member. A flexible sheet of card stock or paper (14) is also provided. An urging device (62) is provided for urging the flexible sheet of card stock or paper (14) adjacent to the template (12) such that an extended portion (54) thereof extends beyond the forming edge of the template (12) and a remaining portion thereof does not extend beyond the forming edge of the template (12). A folding device (26) is provided for urging the extended portion (54) around the forming edge and a securing device (24) is provided for securing the extended portion (54) to the remaining portion of the flexible sheet of card stock or paper (14) after the extended portion (54) has been urged around the forming edge to form a wide edge. The flexible sheet of card stock or paper (14) is held into contact with the template (12) with vacuum pressure. The folding device comprises a roller (26) or a spring loaded bar (86) to force the wide edge of the flexible sheet (14) around the template (12) to form two creases in the flexible sheet (14).
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FIELD OF THE INVENTION
The invention pertains to linear beam electron tubes used to amplify microwaves, particularly waves having amplitude-modulated signals such as television video signals. Klystrons are widely used for this purpose. The invention may also be incorporated in traveling-wave tubes.
A problem which has long bothered television transmitter klystrons has been identified as caused by electrons returning from the collector backward along the beam path toward the electron gun. The harmful electrons travel with approximately the velocity of the original beam. They are called either "reflected electrons" or "high speed secondary electrons".
In passing through the klystron cavities, the stream of returning electrons is velocity modulated by the cavity voltages and thereby bunched by the klystron mechanism to form a beam with modulated current density. This secondary radio-frequency current passing through the input (or other upstream) cavity induces voltage in the cavity exactly the same as modulated primary beam current, since the klystron cavity is completely bi-directional. The final effect is signal regeneration--highly non-linear in amplitude and phase.
Two undesirable effects are produced by such regeneration:
(1) Wiggles in the amplitude transfer characteristic which are manifested as brightness discontinuities in the picture;
(2) A phenomenon known as "sync pulse ringing".
The latter phenomenon may be explained as follows. At the end of each scan line (and frame), a sharp synchronizing pulse is transmitted at an amplitude near the peak saturation output of the transmitter. This pulse has very fast rise and fall time, limited only by the transmitter bandwidth. The gain of the klystron varies during the rise and fall due to the delay in build-up or falloff of voltages in the cavity as a result of their high Qs. When regeneration is added, the voltages can overshoot their equilibrium values, creating a ringing after the rise or fall of the pulse.
PRIOR ART
Several schemes have been tried to prevent such signal regeneration by reducing the number of backstreaming electrons. One scheme depends on the fact that the percentage yield of high speed secondary electrons from a bombarded surface is an increasing function of atomic number. Thus the collector surface is coated with a material of low atomic number. Carbon is effective, but greatly increases the time required to de-gas the tube. U.S. Pat. No. 4,233,539 issued Nov. 11, 1980 to Louis R. Falce and assigned to the assignee of this application, describes an improved aluminum boride coating which is much easier to outgas.
Another prior-art scheme is to modify the geometry of the collector to reduce the probability of secondary electrons re-entering the drift tube. U.S. Pat. No. 3,936,695 issued Apr. 26, 1974 to Robert C. Schmidt and assigned to the assignee of this application, describes a series of baffles inside the collector designed to permit passage of the entering beam, but intercept some of the secondaries.
Still another scheme is described in U.S. Pat. No. 3,806,755 issued Apr. 23, 1974 to E. L. Lien and M. E. Levin and also assigned to the assignee of this application. Its purpose is to statistically reduce the fraction of reflected electrons re-entering the collector entrance aperture by removing the bombarded surface as far as possible from the aperture.
All of the above-mentioned schemes have proven to help reduce regeneration. Each of them, however, only reduces the number of backstreaming electrons, and does not eliminate them.
Several attempts have been made to eliminate backstreaming electrons by magnetic fields transverse to the beam axis. Because magnetic fields deflect moving charges in accord with the "handedness" rule, returning electrons would be deflected in a direction opposite to that direction in which the forward beam would be deflected. Therefore, in principle the returning electrons could be separated from the forward beam and collected. None of these schemes has had any commercial success, due to high cost and to difficulties associated with the asymetric geometry and non-uniform collector dissipation characteristic of these schemes.
Of course, many other examples of more sophisticated schemes utilizing the interaction of magnetic field with an electron beam can be found in the prior art, but they have been directed to other purposes, and have not been of any help regarding the backstreaming electron problem. For example, U.S. Pat. No. 3,398,376 to Hirshfield describes an electron cyclotron maser which generates and amplifies electromagnetic radiation in the microwave and millimeter wave bands. Such generation and amplification is achieved by subjecting a beam of electrons immersed in a longitudinal magnetic field to the action of a corkscrew magnetic or electric field to impart a spiral trajectory, and with the spiralling beam then passing through a cavity having a mode frequency equal to the cyclotron frequency of the spiralling electrons. The action of corkscrew field increases the transverse velocity of the electron beam at the expense of its axial velocity, making possible interaction with the transverse fields in the cavity. Again, however, such schemes have not provided a solution for the backstreaming electron problem.
SUMMARY OF THE INVENTION
An object of the invention is to provide a linear-beam tube having negligible regeneration.
A further object is to provide a tube having uniform collector dissipation.
A further object is to provide a tube which is cheap to manufacture.
These objects are achieved by incorporating along the beam path a direction-sorting trap for electrons. A periodic transverse magnetic field rotates with distance opposite to the sense in which the forward-traveling beam electrons rotate in the axial uniform field used for focusing the beam. The time average of the periodic forces on forward electrons is zero. The period of the transverse field is about equal to the cyclotron wavelength. Returning electrons see the sense of rotation of the transverse field to be the same as their cyclotron rotation, so they are accelerated to larger cyclotron orbits and eventually strike the drift tube and are collected.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic partial section of a klystron embodying the invention.
FIG. 2A is a diagram of the magnetic deflection of an electron in the primary beam.
FIG. 2B is a diagram of the magnetic deflection of a reflected electron.
FIG. 3 is a section of an alternative embodiment.
FIG. 4a and FIG. 4b are a side view and a section view of another embodiment of opposed pairs of discrete magnets arrayed along drift tube 20.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a klystron embodying the invention. Klystrons are widely used as amplifiers in UHF television transmitters. The invention should find its greatest utility in klystrons which suffer from regeneration by backstreaming electrons. Backstreaming also occurs in traveling-wave tubes. The regeneration is less in TWTs because the reflected beam, traveling opposite to the primary rf circuit wave, is not synchronous with it and hence, will be modulated to a much lesser extent than is the case in klystrons. Nevertheless, the invention can produce some improvement in TWT performance.
In FIG. 1 a beam of electrons 10 is drawn from a thermionic cathode 12 by a positive potential on a hollow anode 14. Cathode 12 is heated by radiation from a resistive heater 16. Beam 10 is focused by a focusing electrode 18 to a small diameter to pass thru a long, hollow drift tube 20. Along the length of drift tube 20, beam 10 is kept focused in a pencil shape by the uniform axial field of a solenoid magnet coil 22. The flux return path is provided by a surrounding iron shell 24. After transit of drift tube 20, beam 10 leaves the magnetic field, spreads out and is collected in a hollow collector 26.
Spaced along drift tube 20 are a number of resonant interaction cavities having gaps 30 which are crossed by beam 10. These cavities include an input cavity 32 having a coupling loop 34 for introducing an input microwave signal, an uncoupled cascade cavity 36 and an output cavity 38 having an output loop 40 to extract radio-frequency power. The cavities support the microwave signal in energy-exchanging relationship with the electron beam, with the beam undergoing linear velocity modulation in passing through the successive cavities as is well understood in the art. Of course, klystron cavities are not the only circuit means which can enable such linear velocity modulation; the slow-wave structures of traveling wave tubes are another typical example.
A portion of drift tube 20 between input cavity 32 and output cavity 38 is used for the inventive reflected-electron trap 42. Trap 42 comprises means for producing a periodic magnetic field transverse to the axis of beam 10, the periodicity being such that the direction of the transverse field rotates with distance along the beam. The pitch of rotation is equal to the axial distance an electron travels in one cyclotron period. In FIG. 1 this spiralling transverse magnetic field is produced by a bifilar pair of conductive helices 44, 46 wrapped around but insulated from an extended portion of drift tube 48. Helices 44, 45 are fed direct current in opposing rotational sense as shown by the arrows at the ends of the helices. The magnetic field of these currents traveling through the helices is mainly transverse to the axis of beam 10, and rotates with the pitch of helices 44, 46.
FIG. 2 illustrate the operation of the periodic magnetic field. They represent cross-sections taken at successive transverse planes labeled 0, 1/4, 1/2, 3/4 and 1, across drift tube 48 in FIG. 1, the fractions referring to the fractions of a cycle of rotation of helices 44, 46. The arrows 50, 52, into and out of the plane of the paper, indicate the angular position of helices 44, 46 and the direction of direct current in them. The vector B P indicates the direction of the principal component of the spiralling transverse magnetic field. The vector F indicates the direction of the induced magnetic force on a forward electron 54 (represented by a small circle) as its axial motion into the paper cuts the transverse field B P . The dashed arc 56 indicates the cyclotron trajectory of forward electron 54 in the axial magnetic field B O , which is directed into the paper, and which is provided by solenoid 22.
FIG. 2A represents the forces on and motions of a forward electron 54 moving downstream from cathode to collector. At plane 0 the transverse field force is downward, tending to accelerate electron 54 in its clockwise cyclotron orbit. At plate 1/4, force F is to the right, opposing the cyclotron motion and decelerating it. At plane 1/2 the force is again accelerating the cyclotron motion, and at plane 3/4 again decelerating the cyclotron motion. At plane 1,the conditions are again the same as at plane 0. Thus for an electron of the primary beam, the transverse magnetic field has no net effect, since electron 54 has been accelerated half the time and decelerated the other half, averaging to zero then for a forward electron its normal cyclotron orbit under the influence of the axial magnetic field remains virtually unchanged.
FIG. 2B illustrates the forces and motions of a reflected electron 58, whose axial motion is out of the plane of the paper. Its cyclotron motion under axial field B O will be in the opposite rotational sense to that of a forward electron 54, and is represented by lashed arc 56'. At plane 0, force F is upward, accelerating reflected electron 58 in its cyclotron orbit. At plane 1/4, reflected electron 58 has completed 1/4 of a cyclotron orbit and the transverse field B P has rotated the same amount, so force F is again accelerating the cyclotron motion. This condition continues through the entire orbit if the axial pitch of the transverse field rotation is approximately equal to the axial distance an electron travels during one cyclotron orbital period. As reflected electron 58 is continually accelerated, the diameter of its cyclotron orbit 56' becomes even larger. Eventually it strikes the wall of drift tube 20 and is removed from the backstreaming beam. The principle is analogous to that seen at the first stage of the device of the Hirshfield patent referred to above, in which the transverse velocity of the electron beam is also increased at the expense of the axial velocity. But here, an electron filter or trap is provided, not amplification.
Since the electron trap 42 is essentially axially symmetrical as was seen above in the FIGS. 2 explanations, there is no net displacement of forward beam 10 from its axial symmetry. Thus, no forward electrons are collected, and the distribution of primary beam current reaching the collector is still axially symmetrical. This eliminates some of the problems of non-uniform dissipation encountered in prior-art traps which used lateral deflection of the whole beam.
FIG. 3 is an axial section of a slightly different embodiment wherein the spiralling transverse magnetic field is produced by a pair of permanent magnets 60, 62 spiralling longitudinally around drift tube 20'. They are radially magnetized in opposite direction, so that at any given axial cross-section, their magnetizations are in the same direction, as shown.
FIGS. 4A and 4B are respectively a side view and a section perpendicular to the axis of another embodiment. Here, instead of the expensive long spiral magnets of FIG. 3, opposed pairs of discrete magnets 64, 66 are arrayed successively along drift tube 20". For each such approved pair, for example magnets 64 and 66, the magnetization is in the same direction (as in FIG. 3). The successive opposed pairs rotate in their orientation with distance along the axis, with a pitch as defined above. In the illustrated embodiments, the pairs are shown as spaced by 1/4 the pitch and rotated by 90° from the preceding pair. This is not a requirement. Any integral number of pairs greater than one could be used to make one axial pitch.
It will be obvious to those skilled in the art that the invention might be embodied in a variety of other forms. Other velocity-modulated linear-beam tubes other than those above discussed can benefit from the invention. Indeed, this invention is also applicable in other vacuum tube applications, including density-modulated electron-beam tubes, CRTs, and for ion-trap applications. The described embodiments are exemplary and not limiting. The invention is to be limited only by the following claims and their legal equivalents.
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Some electrons reflected from the collector of a klystron form a beam current flowing back toward the input end of the tube. This beam is modulated and can carry a regenerate signal which distorts the tube's performance when amplifying a television signal. The reflected electrons are removed by a spiralling transverse magnetic field having a pitch equal to the cyclotron wavelength in the axial magnetic field used to focus the beam. The rotative sense of the spiral is such that forward-going beam electrons are not affected but returning electrons are accelerated in their cyclotron orbits until they are driven outside the beam and are collected.
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FIELD OF THE INVENTION
The present invention relates to temperature measurement. More particularly, the invention relates to a method and apparatus for the accurate measurement of the core temperature of a body by sensing the temperature at points outside the body.
BACKGROUND OF THE INVENTION
Temperature measurements are widespread and essential in many fields of modern life, such as industry, science, medical care and many other basic human needs. A lot of processes in industry are temperature controlled or strongly affected by temperature. Therefore, accurate temperature measurements are required for carrying them out properly. The same requirements apply also in science, when experimentation and research often require temperature sensing. Human body temperature measurements are mandatory in many cases. Accurate measurement of human body temperature is carried out as a routine in hospitals and clinics and is generally required for medical care in view of its symptomatic significance.
Mercury thermometers are used frequently for measuring the temperature of the human body orally, in the axilla or rectally. However, in spite of the fact that such measurements are in themselves accurate, they often poorly reflect the inner temperature of the human body, since there is a substantial difference between said temperature and that of the sensed area and, further, the temperature that is read depends of the way the thermometer tip is held in the measurement. Another reason for inaccuracy is associated with different modes of operation of the thermometer. For instance, if the patient is a child, using the thermometer orally, the heat conduction from his mouth to the thermometer may vary according to the orientation of the tip in the child's mouth and the fact that he opens it from time to time. Another disadvantage of the mercury thermometer is its fragility. In addition, it should be sterilized after each use.
Oral and rectal measurements are also inconvenient for the patient, and in some cases may even be painful. Surface or external measurements, such as by thermometers attached to the skin, are less inconvenient but even less accurate. Optimally, these thermometers measure the skin temperature, which may substantially differ from the relevant inner body temperature by as much as 10° C. and even more, if the contact with the skin is poor. Thermal conduction and heat flow affect surface temperature measurements. For example, the human body is not well insulated from the ambient and there is a constant heat flow from the skin to the ambient and from the body core to the skin. Thus, under normal conditions, the skin temperature is always colder than the core temperature to be measured. In addition, thermal conduction between the skin and the thermometer is affected by several factors, such as adhesion and skin humidity. Additionally, heat is lost by the thermometer to the ambient in an amount depending on the insulation of the thermometer.
Another disadvantage associated with conventional thermometers is the time required to take a temperature. At least a minimum time, which may be more than three minutes, is needed for a reasonable measurement accuracy. Some patients, for instance children, do not stand such relatively lengthy measurements. Further, in hospitals, reading the temperature of each patient several times a day requires an unacceptable part of the nurse's duty time.
Other thermometers use an Infra-Red technology, thereby reducing the measurement time. Temperature is read by inserting the sensor into the ear channel measuring the amount of the IR radiation emitted from the channel, and converting it to temperature values. Still, this measurement is relatively expensive, and often does not correlate well with the body temperature.
U.S. Pat. No. 3,702,076 discloses an electronic thermometer, which provides a temperature measurement output as a direct digital, display. U.S. Pat. No. 3,942,123 describes an electronic thermometer based on an electrical bridge with a thermistor in one arm of the bridge. A shunting impedance is switched into and out of the balancing arm of the bridge in a manner providing indication about the measured temperature, according to the thermistor resistance value. U.S. Pat. No. 3,926,053 describes an apparatus of non-contact surface temperature determination on a rotating part, which comprises a sensing probe unit for temperature and distance detection and a capacitive excursion measurement system. However, each apparatus described in said patents provides only indications about the surface temperature, and still lacks the core temperature measurement capability.
It is an object of the present invention to provide a method and an apparatus for accurate measurements of body core temperatures, which overcome the drawbacks of prior art methods and devices.
It is another object of the invention to provide a non-invasive method and apparatus, which permit the accurate estimation of body core temperature from temperature measurements external to the body.
It is a further object of the invention to provide a method and apparatus for the estimation of body core temperatures, which permit to reduce the time required for the measurement without significant loss of accuracy.
It is a still further object of the invention to provide a method and apparatus which achieve the aforesaid objects in the measurement of the human body temperature without causing discomfort to the patient.
Other purposes and advantages of the invention will appear as the description proceeds.
SUMMARY OF THE INVENTION
In describing the invention, it will be assumed that the body, the temperature of which is to be measured, has an inner portion the temperature of which is substantially constant (hereinafter called “the body core” or “the core”), a surface, from which heat is dissipated into the surrounding ambient, and a layer between the core and the surface (which may be called “subsurface layer”) wherein the temperature gradually decreases from that of the core to that of the surface. In the case of a steady heat flow and a constant conductivity throughout the subsurface layer, said temperature decrease is linear. It is assumed that since there are no heat sources in the body except the core, the temperature falls as a monotonous decreasing function from the core to the surface. Under these conditions, in steady state, if it is found that two intermediate points along a path between two extreme points have the same temperature, the two extreme points must be at the same temperature. This invention is based on the concept that, if a path for heat flow can be created between the core of the body, the temperature of which is to be measured (hereinafter, briefly “the body”), and points outside said body, and the flow of heat along this path can be controlled so that two points of said path are at the same temperature, under thermal equilibrium, this indicates that heat flow has ceased and their temperature will be the same as that of the core.
This invention therefore provides a method of measuring the temperature of the core of a body, which comprises:
a) providing a heat conductive space outside the body and in contact with its surface;
b) monitoring the difference of the temperatures of two points located within said space and at different distances from said body surface;
c) if said temperature difference indicates that heat is flowing from the body surface outwards, generating heat in said space, whereby to reduce said temperature difference; and
d) monitoring said temperature difference, and assuming the temperature of one of said two points, when said temperature difference is zero, as the temperature of body core.
Preferably, said body core temperature is displayed.
In one variant of the invention, the generation of heat in the heat conductive space is continued until the temperature of said two points located within said space has been equalized and the temperature of one of said two points, preferably the one nearer the body surface, is measured. In another variant of the invention, which accelerates the temperature measurement process, heating of the heat conductive space is discontinued before the temperatures of the aforesaid two points have been equalized, and the temperature which one of said points would have assumed if it had been equalized is calculated by extrapolation. The moment in which the temperature difference between said two points becomes zero or would become zero, will be called “the zero moment”.
In order that the assumption that the method of the invention should yield sufficiently accurate result, a quasi-thermal steady state condition must have been reached. This means that at the zero moment the temperature is substantially constant along a path from the body core to said two points within the heat conductive space, and therefore the body core, the body surface and said points are at the same temperature. This is true, in spite of the fact that heat will continue to flow from the body core to the body surface and from this latter to the ambient along paths that do not pass through the heat conductive space and the temperature will not be constant along said paths. However, if the heat is transmitted too rapidly before equilibrium is reached, the thermometer reading may not be sufficiently accurate. Care should be taken therefore to apply the appropriate power to the heater, which can be determined, if necessary, by a calibration of each type and size of thermometer according to the invention. From the thermodynamical viewpoint, the slower the heating, the more accurate the temperature reading. Therefore, in order to obtain a precise measurement without requiring too long a time, it is possible to divide the temperature measurement process into two stages: in the first stage the heating is fast and its zero moment provides a first, approximate temperature reading, and in the second stage the heating is slow and said approximate reading is corrected to reach a new zero moment providing the final, accurate reading. Both stages are short, because in the first the heating is fast and in the second, while the heating is slow, only a small correction of the temperature reading is effected.
The heat conductive space should be thermally insulated on all its surfaces, except where it is intended to contact the surface of the body.
Correspondingly, this invention provides an apparatus for measuring the temperature of the core of a body, which comprises:
I—an element (which is a sensing unit and will be hereinafter called “capsule), the inside of which is heat conductive, preferably with a high heat conductivity and a low heat capacity, which has a surface adapted to be placed in contact with the surface of the body the temperature if which is to be measured and is thermally insulated on all its other surfaces;
II—a heating element for heating the inside of the capsule;
III—two temperature sensors for measuring the temperatures of two points inside the capsule and/or the difference of said temperatures
IV—a control module, including a power supply; and
V—a connection between the capsule and the control module.
Preferably, the apparatus further comprises a display, which can be e.g. a liquid crystal or a light emitting diode display.
Preferably, the temperature sensors are thermocouples.
Hereinafter, the term “capsule” will be used to designate both the element the inside of which is heat conductive and the heat conductive space defined by said element.
The control module comprises a power source for activating the heating element, a temperature measurement circuit connected to the thermocouples, a temperature display, and a controller, which might be e.g. an ASIC, receiving input from the thermocouples and correspondingly controlling the activation of the heater in an on-off or proportional manner. Preferably, the temperature measurement circuit has two functional modes: measuring the difference of the temperatures of the aforesaid two points inside the capsule, or measuring the temperature of one of said points.
The aforesaid two points are at different distances from the capsule surface adapted to be placed in contact with the surface of the body, and preferably located close to said surface and more preferably at or near a perpendicular to said surface.
The surface of the capsule that is to be placed in contact with the surface of the body will be adapted to said surface and to the nature of the body. If the apparatus is used to measure the temperature of the human body, it can be rendered a heat conductive adhesive so that it may be held firmly on the skin.
The connection between the capsule and the CM can be established by providing a first interface on the capsule and a second interface on the module and operatively connecting the interfaces by means of conductors, when required. Such connections are in themselves conventional and need not be particularly described. Alternatively, capsule and CM may be permanently connected, or form a unitary structure.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a block diagram of a thermometer, according to one preferred embodiment of the invention;
FIG. 2 is a cross-section of the capsule of the thermometer, according to one preferred embodiment of the invention;
FIG. 3 schematically illustrates the temperature gradients between the body core and the capsule before activating the thermometer;
FIG. 4 schematically illustrates the temperature distribution between the body core and the capsule at the time of measurement, according to one preferred embodiment of the invention;
FIG. 5A is a diagram illustrating the variation of the difference of the temperature of the two thermocouples housed in the capsule as a function of time;
FIG. 5B is a diagram illustrating the variation of the body surface temperature as a function of time;
FIG. 6 schematically illustrates the construction of the capsule of the thermometer, according to an embodiment of the invention; and
FIGS. 7A and 7B schematically illustrates the temperature measurement process, according to an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The embodiments that will be described are thermometers for measuring the temperature of the human body. This, however, should not be construed as a limitation, as the invention can be applied advantageously to other temperature measurements, particularly in industry and in science.
FIG. 1 is a block diagram of a non-invasive thermometer, according to one preferred embodiment of the invention, which is adapted to be attached to the surface of a body and to measure the core temperature. A sensing unit or capsule 10 , to be placed in contact to the body surface and retained thereon, contains, within a body having high thermal conductivity and low thermal capacity and provided with a thermally insulated cover, not indicated in the diagram, an electrical heater 11 , two thermocouple elements, 12 and 19 , and an interface connector 13 for operatively connecting it with the Control Module. A Control Module (CM) 14 contains a power supply 15 , a temperature measurement and control circuit 16 connected to the thermocouples, a temperature display 17 , and an interface connector 18 .
As used herein, the terms “measurement” and “measuring” are meant to include indirect measurement, i.e., the estimation of the temperature of a body core from temperatures measured outside said body.
According to one preferred embodiment of the method of the invention, temperature measurement is started by applying the capsule to the surface of the body, the temperature of which is to be measured, and connecting the capsule to the CM through connectors 13 and 18 . Thermocouple junction 12 “senses” the temperature at one point in the capsule and thermocouple junction 19 “senses” the temperature at another point in the capsule, the two junctions being at different distances from the capsule surface that is intended to be applied to the body surface. Though thermocouples are described in this embodiment, other temperature sensors adapted to sense the temperature of points inside the capsule could be used.
The temperature measurement process is schematically illustrated in FIGS. 7A and B, wherein the two junctions of the thermocouples 12 and 19 are indicated as J 1 and J 2 respectively. FIG. 7A shows the two junctions J 1 and J 2 , shortened by wires 62 - 63 . The voltage difference generated between the two thermocouple junctions is fed, via the connectors, into the CM 14 , which amplifies and reads the difference V J1 -V J2 between the two voltages, corresponding to the temperature difference between the two junctions J 1 and J 2 . If said voltage difference indicates that heat is flowing from the surface of the body, and therefore from its core, to the capsule, i.e. t 19 >t 12 , the temperature measurement and controller circuit connects the power supply 15 to the heater 11 . As a result, the body heats and the temperatures of junctions 12 and 19 rise, but that t 12 increases more than t 19 , as the first is closer to the heater, and the difference between them is reduced. When said temperature difference, and therefore said voltage difference, has become zero, the situation becomes that illustrated in FIG. 7 B. The measurement and control circuitry 16 reads the temperature at one thermocouple junction (usually at the junction which is closer to the body surface), which, in FIG. 7B is assumed to be junction J 1 , by measuring the voltage difference between it and a reference point. The reference point, at this stage, is no longer the second thermocouple, but a cold junction compensation CJ, which is a junction at a known reference temperature (V CJ ), or, preferably, an electronic unit that carries out the same function, such as are well known to expert persons. The measured voltage difference is therefore V JI -V CJ . The measurement and control circuitry 16 displays the reading on display 17 and disconnects the power supply 15 from the heater 11 . Alternatively, for continuous measurements, the control 16 does not shut off the heater, but only reduces its power, so that a predetermined, small temperature difference remains. The display may be of any suitable type known in the art and therefore need not be described.
According to another embodiment of the invention, the temperature of the body core may be read, with slightly lower accuracy, as the aforesaid voltage difference approaches zero, i.e., when it has become lower than a small predetermined value; or it may estimated by extrapolation, as more fully explained hereinafter.
FIG. 2 is a cross-section of a capsule generally indicated at 20 , attached to the surface 27 of a human body 26 , according to a preferred embodiment of the invention. The capsule 20 contains a heater 21 , two thermocouple junctions and a heat conducting material 24 . The first thermocouple junction consists of wires 23 a and 28 a , is located at point “A”. The second thermocouple junction, consists of wires 23 b and 28 b , is located at point “B”. An interface connector 25 , attached to the capsule, comprises contacts carrying data from the two thermocouple junctions, and additional electric contacts for supplying heating power to the heater 21 (which may be, for instance, a resistor).
The temperature gradients in this assembly, before operating the heater, are shown in FIG. 3 . After adhesion of the capsule 29 to the surface (the skin, in this case) 27 , the system has reached a thermal equilibrium, with a constant heat flow from the core 26 (hot area) to ambient air 33 (cold area) through the sub-surface portion of the body and its surface. In equilibrium, several equi-temperature lines (dotted lines AA, BB in FIG. 2) are formed in said sub-surface portion, where the temperature, that each line represents, decreases upon approaching the surface 27 . This indicates an inward positive temperature gradient and consequently an outward flow of heat, shown by a plurality of outgoing arrows (FIG. 3 ). Therefore, before operating the heater, there is a temperature gradient between the two measurement points “A” and “B”, indicating a temperature difference between the surface 27 and core 32 temperatures, which would introduce an error in conventional temperature readings.
Looking back on FIG. 2, before operating the thermometer, the core 26 is at the body temperature normally of 37° C. As a result of heat losses, the surface 27 is at lower temperature, 30° C. The ambient is at normal room temperature of 24° C. According to one preferred embodiment of the invention, the thermometer is operated by connecting the capsule 20 to the CM, via the interface connector 25 and another interface connector carried by the CM and not shown in the drawings. Alternatively, the CM can be integral or permanently connected with the capsule. When said connection has been made, the first and second thermocouple junctions are affected by the temperatures at points “A” and “B”, point “B” being in close proximity to the surface 27 . The measurement and controller unit of the CM reads the voltage difference generated between the thermocouple junctions (by activating a switch so as to short wires 62 and 63 and measure the voltage difference between wires 61 and 64 —see FIGS. 7 A and 7 B), and, since said difference indicates that the temperature is higher at “B” than at “A”, activates the heater 21 by connecting it to the power supply. As a result, there is a heat flow from the heater 21 via the heat conducting material 24 to points “A” and “B” and the body core. This heat flow elevates the temperature at both points, as well at the portion 30 of the surface 27 that is contact with the capsule and the corresponding subsurface areas. Consequently, the flow of heat from core 26 to the inside of the capsule decreases, and the temperature difference between points “A” and “B”, that was due to said heat flow, gradually decreases to zero. It is to be noted that the temperature difference caused by the heater 21 between those two points, though they may be at different distances from the heater, is offset by the heat flow from the core. The kinetics of the temperature changes are fast, due to the high thermal conductivity and low thermal capacity of the capsule body 24 . The voltage difference between the two thermocouple junctions is also zeroed, indicating zero temperature gradient. At this moment (hereinafter called “the zero moment”) the temperature of the portion 30 of the body surface 27 and the temperature at points “A” and “B” within the capsule, equal the body core temperature. The measurement and controller circuit 16 , registering the zeroing of the voltage difference, disconnects the wires 62 and 63 (see FIGS. 7 A and 7 B), i.e., separates between the two thermocouple junctions, and a temperature measurement is taken by one of the junctions, in this case junction J 1 which is located at point “B”, by connecting it to the reference point CJ (which could be a “cold junction compensation”, see FIG. 7 B). On condition, as explained hereinbefore, that a thermal equilibrium has been reached, the temperature of point B is the same as that of the portion 30 of the body surface and this latter is the same as that of body core. Thus the measurement represents the desired body core temperature with high accuracy and said temperature is displayed on the temperature display at the CM, while the heater 21 is disconnected from the power supply.
FIG. 4 illustrates the temperature distribution between the body core and the capsule at the zero moment, according to a preferred embodiment of the invention. The temperature at any point within the core of the capsule, constituted by heat conductor 24 , and in particular at the portion 30 of body surface 27 , is equal to the temperature of the body core, the temperature gradient, along any line going from the body core to the capsule core through said surface portion is zero, and the temperature at any point on such line is that of the body core, 37° C. in this example. Far from the capsule, each equi-temperature line pattern is similar to the pattern before operating the thermometer, as shown in FIGS. 2 and 3 above, viz. essentially parallel to the surface 27 . When approaching the surface portion 30 , and therefore the capsule, each equi-temperature line bends outward and terminates at the borders of the capsule core, wherein the temperature has been raised by the heat of the controlled heater to coincide with the temperature of the body core. An example of a 35° C. equi-temperature line pattern, curved toward outwardly to form curve segments CC-DD, is shown.
In one preferred embodiment of the invention it is desired to reduce the measurement time, without substantial degradation of measurement accuracy, by an extrapolation. This will be understood by reference to FIGS. 5A and 5B. FIG. 5A shows how the voltage difference between the two junctions J 1 and J 2 , indicated as “I”, varies with time. It is I 0 up to the moment t 0 where the thermometer is activated, i.e., the time when the heater starts heating. From that moment on, it decreases for example linearly up to a time t 2 , when it becomes zero, and when, ordinarily, the temperature of the thermocouples would be read. If that reading is carried out at a time t 1 <t 2 , the time t 2 can be estimated from the function describing the change in the temperature difference during the time t 1 -t 0 .
FIG. 5B schematically illustrates the change in the temperature of the body surface Ts as a function of time. The initial surface temperature is Ts 0 . The surface temperature gradually rises until the zero time t 2 where the surface temperature of the body is equal to its core temperature, indicated in FIG. 5B by Tc. At time t 1 the surface temperature is Ts 1 , lower than Tc but higher than Ts 0 . If Ts 0 and Ts 1 are measured, and t 2 has been calculated by extrapolation, Tc, which would be the value of Ts at time t 2 , can also be calculated by extrapolation. The controller can easily be programmed to carry out the calculations.
The measurement accuracy is slightly affected by this extrapolation and by the fact that the assumption on which it is based may not be fully accurate. According to one preferred embodiment of the invention, high accuracy is achieved by carrying out a thorough calibration of the device with a typical human body, prior to actual measurements.
A second measurement may be taken by not disconnecting the heater at the zero moment by letting it overheat and then disconnecting it and taking a measurement as the system cools towards a new zero moment. In this way, temperature measurements can be taken almost continuously from a sick patient. In this case, the heater output will be modulated rather than connected and disconnected. Additional factors which affect the measurement time and accuracy are the heat conductance and the heat capacity of the capsule. As has been said, high heat conductivity is desired, for quick heat transfer from the heater to the surface and vice versa, and so is low heat capacity. Furthermore, the power of the heater may be reduced for capsules with low heat capacity.
According to one preferred embodiment of the invention the inside of the capsule is constructed specially to achieve high heat conductivity and low heat capacity, as illustrated in FIG. 6. A metallic skeleton is constructed from two metal sheets, 60 and 61 , with high heat conductivity and low heat capacity, such as aluminum or copper. Two metal bars, 63 and 64 , or a plurality of such bars, connect between metal sheets 60 and 61 , forming a high heat conducting path without short circuiting so as to maintain a temperature difference (a short circuit would prevent that). The length and diameter of the bars is adjusted to maintain an appropriate gradient. According to one preferred embodiment of the invention, these metallic connections, as well as the whole skeleton, may be fabricated as a conductive mesh, using etching and/or photochemical techniques, or by masked microelectronics evaporation. The use of a plurality of such thermal short-circuits increases the thermal conductivity of the capsule core, with minor increase in thermal capacity.
According to one preferred embodiment of the invention, the capsule is permanently attached to the skin of each patient for as long as desired to obtain repetitive temperature readings. In this case, a plurality of fast and accurate temperature measurements, from different patients, can be taken by a nurse having one CM. The nurse connects the interface connector of the CM to the mating connector of the capsule attached to a patient, waits a predetermined time (required for accurate extrapolation), records the reading for that patient and moves to the next patient. In this way, substantial time is saved, and the need for sterilization of the thermometer is dispensed with.
According to another preferred embodiment of the invention, the capsule is attached to a diaper (or to a disposable diaper) worn by a patient (baby), in the upper area, having relatively low moisture. In this case the thermal contact of the capsule with the skin may be improved by a heat conducting paste, such as silicon paste, an elastic band, etc.
According to still another preferred embodiment of the invention, a similar method can be applied for sensing the temperature inside an oven from the outside. The measurement time depends upon the inherent insulation of the oven from the ambient. Relatively low levels of insulation results in reduced measurement time.
It will be understood that the above examples and description have been provided only for the purpose of illustrations, and are not intended to limit the invention in any way, and that, the invention can be carried out by skilled persons with many modifications, variations and adaptations, without departing from its spirit or exceeding the scope of the claims.
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A method of measuring the temperature of the core of a body includes: a) providing a heat conductive space outside the body and in contact with its surface; b) monitoring the difference of the temperatures of two points located within the space and at different distances from the body surface; c) if the temperature difference indicates that heat is flowing from the body surface outwards, generating heat in the space in order to reduce the temperature difference; d) monitoring the temperature difference; and e) assuming the temperature of one of the two points, when the temperature difference is zero, as the temperature of body core.
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RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Patent Application No. 2003-7547, filed Feb. 6, 2003, the contents of which are incorporated herein by reference in their entirety.
BACKGROUND OF INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a method of manufacturing a semiconductor integrated circuit and a semiconductor integrated circuit manufactured thereby and, more particularly, to a method of manufacturing a semiconductor integrated circuit using a selective disposable spacer technique and a semiconductor integrated circuit manufactured thereby.
[0004] 2. Description of Related Art
[0005] Metal-Oxide-Semiconductor (MOS) transistors exhibit various advantages as compared to bipolar transistors. For example, the MOS transistors are suitable for a semiconductor integrated circuit (IC) having a high integration density and a low operation voltage with low power consumption. Therefore, most semiconductor ICs employ the MOS transistors as switching elements.
[0006] As semiconductor ICs have become more highly integrated, MOS transistors have been scaled down. As a result, the electrical characteristics and reliability of such semiconductor ICs are sometimes degraded thereby causing malfunctions. For example, attempts to increase device integration density in semiconductor ICs have typically resulted in reduction of the widths of gate electrodes of MOS transistors and in the reduction of junction depths of source/drain regions thereof. In such devices, electrical resistances of the gate electrodes and the source/drain regions are increased, and the reliability (for example, hot carrier effect and short channel effect) and the electrical characteristic.(for example, signal delay time) of the MOS transistors can be degraded. In order to solve these problems, a self-aligned silicide (SALICIDE) technique and a lightly doped drain (LDD) structure have been widely used in fabrication of MOS transistors. Gate spacers are generally formed on the sidewalls of the gate electrodes in order to realize the LDD-type source/drain structure and the SALICIDE technique.
[0007] The fabrication technology of the semiconductor ICs having the gate spacers is taught in U.S. Pat. No. 6,043,537 to Jun et al., entitled “Embedded memory logic device using self-aligned silicide and manufacturing method therefore.”
[0008] The manufacturing method of semiconductor devices according to the U.S. Pat. No. 6,043,537 includes preparing a semiconductor substrate that has a DRAM cell array region and a peripheral circuit region. Active regions are formed at the semiconductor substrates. Words lines and gate electrodes are formed in the DRAM cell array region and the peripheral circuit region, respectively. The word lines are formed to extend across the active regions in the DRAM cell array region, and the gate electrodes are formed to extend across the active regions in the peripheral circuit region. Impurity ions are then implanted into the active regions using the word lines and the gate electrodes as ion implantation masks, thereby forming low concentration source/drain regions. As a result, first and second low concentration source regions as well as a common low concentration drain region are formed at the respective active regions in the DRAM cell array region. The first and second low concentration source regions correspond to storage node junctions of DRAM cells.
[0009] A conformal spacer layer is formed on an entire surface of the semiconductor substrate having the low concentration source/drain regions. A photoresist pattern is formed on the spacer layer. The photoresist pattern is formed over the first and second low concentration source regions. The spacer layer is anisotropically etched using the photoresist pattern as an etch mask. Accordingly, spacers are formed on the sidewalls of the word lines and the gate electrodes. However, the conformal spacer layer on the first and second low concentration source regions is not anisotropically etched due to the photoresist pattern. Therefore, spacer layer patterns acting as salicide blocking patterns are formed on the first and second low concentration source regions. After removing the photoresist pattern, impurity ions are implanted into the active regions using the word lines, the gate electrodes, the spacers and the salicide blocking patterns as ion implantation masks, thereby forming high concentration source/drain regions. As a result, LDD-type source/drain regions are formed in the active regions of the peripheral circuit regions, and LDD-type common drain regions are formed in the active regions of the DRAM cell array region.
[0010] Subsequently, a metal layer is formed on an entire surface of the semiconductor substrate having the LDD-type source/drain regions, and the metal layer is annealed to form a metal silicide layer. As a result, the metal silicide layer is selectively formed on the word lines, the common drain regions, the gate electrodes and the source/drain regions in the peripheral circuit region. In other words, the metal silicide layer is not formed on the storage nodes, i.e., the first and second low concentration source regions.
[0011] Eventually, according to the U.S. Pat. No. 6,043,537, the leakage current that flows through the storage node junctions can be reduced.
[0012] In addition, spacers are widely used in fabrication of self-aligned contact holes. In this case, the spacers are formed of an insulating layer (for example, a silicon nitride layer) having an etching selectivity with respect to a conventional interlayer insulating layer.
[0013] However, if spaces between interconnection lines such as the word lines are reduced, actual areas of the source/drain regions exposed by the self-aligned contact holes are greatly reduced because of the presence of the spacers.
SUMMARY OF THE INVENTION
[0014] The present invention provides, among other things, a method of manufacturing a semiconductor integrated circuit using a selective disposable spacer technique and a semiconductor integrated circuit manufactured thereby.
[0015] In one embodiment of the invention, a method of fabricating a semiconductor integrated circuit includes forming a device isolation layer at a predetermined region of a semiconductor substrate to define a first active region and a second active region. A plurality of first gate patterns extend across the first active region. The regions between the first gate patterns include a first opening having a first width and a second opening having a second width greater than the first width. The device isolation layer exposed by the first opening is selectively removed. A second gate pattern is formed across the second active region. Low concentration source/drain regions are formed in the second active region located on both sides of the second gate pattern. Spacers are formed on sidewalls of the second opening and on sidewalls of the second gate pattern. Also, a spacer layer pattern filling the first opening is concurrently formed with the spacers. High concentration source/drain regions adjacent the low concentration source/drain regions are formed in the second active region to provide LDD-type source/drain regions including the low concentration source/drain regions and the high concentration source/drain regions. The spacers are then removed to expose the sidewalls of the second opening and the second gate pattern. During removal of the spacers, a recessed spacer layer pattern remains in the first opening.
[0016] In some embodiments, a first impurity region having a line-shaped configuration may be formed at the surface of the semiconductor substrate exposed by the first opening, prior to formation of the second gate pattern. Then, a second impurity region having an island-shaped configuration may be formed at the surface of the first active region exposed by the second opening. Alternatively, the first and second impurity regions can be concurrently formed using a single step ion implantation process.
[0017] In accordance with another embodiment, the semiconductor integrated circuit includes a device isolation layer formed at a semiconductor substrate to define first and second active regions. A plurality of first gate patterns extend across the first active region. The regions between the first gate patterns include a first opening having a first width and a second opening having a second width greater than the first width. A second gate pattern extends across the second active region. The first opening is filled with a recessed spacer layer pattern. LDD-type source/drain regions are formed in the second active region located on both sides of the second gate pattern.
[0018] In some embodiments, a first impurity region having a line-shaped configuration may be disposed at the surface of the semiconductor substrate underneath the first opening. Also, a second impurity region having an island-shaped configuration may be disposed at the surface of the first active region underneath the second opening. As a result, the first impurity region is covered with the recessed spacer layer pattern.
[0019] In accordance with one embodiment, the method of manufacturing a flash memory device includes providing a semiconductor substrate having a cell array region and a peripheral circuit region. A device isolation layer is formed at a predetermined region of the semiconductor substrate to define a cell active region and a peripheral circuit active region in the cell array region and the peripheral circuit region respectively. A stacked gate layer and a peripheral circuit gate layer are then formed in the cell array region and the peripheral circuit region respectively. The stacked gate layer is patterned to form a plurality of stacked gate patterns that extend across the cell active region. The regions between the stacked gate patterns include first openings having a first width and second openings having a second width greater than the first width. The device isolation layer exposed by the first openings is selectively removed. The peripheral circuit gate layer is patterned to form a peripheral circuit gate electrode that extends across the peripheral circuit active region. Impurity ions are implanted into the peripheral circuit active region using the peripheral circuit gate electrode as an ion implantation mask. As a result, low concentration source/drain regions are formed at the peripheral circuit active region. Spacers are formed on the sidewalls of the second openings and on sidewalls of the peripheral circuit gate electrode. Spacer layer patterns filling the first openings are concurrently formed with the spacers. High concentration source/drain regions are formed at the peripheral circuit active region using the peripheral circuit gate electrode and the spacers on the sidewall of the peripheral circuit gate electrode as ion implantation masks to provide LDD-type source/drain regions including the low concentration source/drain regions and the high concentration source/drain regions. The spacers are removed to expose the sidewalls of the second openings and the peripheral circuit gate electrode. During removal of the spacers, recessed spacer layer patterns remain in the first openings.
[0020] In some embodiments, before forming the peripheral circuit gate electrode, line-shaped common source regions and island-shaped drain regions may be formed at the surface of the semiconductor substrate exposed by the first openings and at the surface of the cell active region exposed by the second openings respectively. As a result, the common source regions are covered with the spacer layer patterns.
[0021] In accordance with another embodiment, the flash memory device includes a semiconductor substrate having a cell array region and a peripheral circuit region. A device isolation layer is formed at a predetermined region of the semiconductor substrate. The device isolation layer defines a cell active region and a peripheral circuit active region in the cell array region and the peripheral circuit region, respectively. A plurality of stacked gate patterns extend across the cell active region. The regions between the stacked gate patterns include first openings having a first width and second openings having a second width greater than the first width. A peripheral circuit gate electrode extends across the peripheral circuit active region. The first openings are filled with recessed spacer layer patterns. LDD-type source/drain regions are disposed at the peripheral circuit active region located on both sides of the peripheral circuit gate electrode.
[0022] According to still another embodiment, line-shaped common source regions may be disposed at the surface of the semiconductor substrate underneath the first openings. Also, island-shaped drain regions may be disposed at the surface of the cell active region underneath the second openings. As a result, the common source regions are covered with the recessed spacer layer patterns.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Exemplary embodiments of the present invention will be readily apparent to those of ordinary skill in the art upon review of the detailed description that follows when taken in conjunction with the accompanying drawings, in which like reference numerals denote like elements, and in which:
[0024] [0024]FIG. 1 is a top plan view illustrating a semiconductor integrated circuit according to the present invention;
[0025] [0025]FIGS. 2A to 14 A are sectional views, taken along line I-I′ of FIG. 1, illustrating a fabrication method of a semiconductor integrated circuit according to an embodiment of the present invention;
[0026] [0026]FIGS. 2B to 14 B are sectional views, taken along line II-II′ of FIG. 1, illustrating a fabrication method of a semiconductor integrated circuit according to an embodiment of the present invention;
[0027] [0027]FIGS. 2C to 14 C are sectional views, taken along line III-III′ of FIG. 1, illustrating a fabrication method of a semiconductor integrated circuit according to an embodiment of the present invention; and
[0028] [0028]FIGS. 2D to 14 D are sectional views, taken along line IV-IV′ of FIG. 1, illustrating a fabrication method of a semiconductor integrated circuit according to an embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0029] The present invention will now be described more fully hereinafter in conjunction with a NOR-type flash memory device with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. For example, the present invention may be applied to NAND-type flash memory devices within spirit and scope of the invention. In the drawings, the thickness of layers and regions are exaggerated for clarity. Like reference numerals refer to like elements throughout the specification.
[0030] [0030]FIG. 1 is a top plan view of a NOR flash memory device according to an embodiment of the present invention, and FIGS. 14A, 14B, 14 C and 14 D are sectional views taken along lines I-I′, II-II′, III-III′ and IV-IV′ of FIG. 1, respectively.
[0031] Referring to FIGS. 1, 14A, 14 B, 14 C and 14 D, a semiconductor substrate 1 has a cell array region A and a peripheral circuit region B surrounding the cell array region A. The peripheral circuit region B may correspond to a high voltage MOS transistor region or a low voltage MOS transistor region. In this embodiment, for simplicity, it is assumed that the peripheral circuit region B is an NMOS transistor region. A device isolation layer is located at a predetermined region of the semiconductor substrate 1 . The device isolation layer defines first and second active regions in the cell array region A and the peripheral circuit region B, respectively.
[0032] In more detail, the device isolation layer defines cell active regions 37 c (FIG. 1) and a peripheral circuit active region 37 p (FIG. 1) in the cell array region A and the peripheral circuit region B, respectively. Preferably, the device isolation layer includes a cell device isolation layer 39 b (FIG. 14A) formed in the cell array region A and a peripheral circuit device isolation layer 39 a (FIG. 14A) formed in the peripheral circuit region B. In this case, the cell device isolation layer 39 b is preferably thinner than the peripheral circuit device isolation layer 39 a.
[0033] As shown in FIGS. 1 and 14 c, a plurality of first gate patterns 52 a, e.g., a plurality of stacked gate patterns, extend across the cell active regions 37 c. Each of the stacked gate patterns 52 a includes a tunnel insulating layer pattern such as a tunnel oxide layer pattern 19 a, a floating gate FG, an inter-gate dielectric layer 47 and a control gate electrode CG, which are sequentially stacked. The control gate electrodes CG extend across the cell active regions 37 c and the cell device isolation layer 39 b between the cell active regions 37 c. Further, the floating gates FG are located between the control gate electrodes CG and the cell active regions 37 c. Each of the control gate electrodes CG may include first and second control gate electrodes 49 c and 51 c, which are sequentially stacked, and each of the floating gates FG may include a lower floating gate 21 f and an upper floating gate 41 f, which are sequentially stacked.
[0034] On the other hand, as shown in FIG. 1, the regions between the stacked gate patterns 52 a define first spaces having a first width S1 and second spaces having a second width S2 greater than the first width S1.
[0035] Referring to FIG. 14A, the first spaces are filled with recessed spacer layer patterns 65 a. First impurity regions 55 having a line shape, e.g., common source regions are formed at the surface of the semiconductor substrate under the recessed spacer layer patterns 65 a. As a result, the common source regions 55 are covered with the recessed spacer layer patterns 65 a. In this case, as shown in FIG. 14B, the recessed spacer layer patterns 65 a also fill the regions where the cell device isolation layer between the cell active regions 37 c is removed. In addition, second impurity regions 57 having an island shape, e.g., drain regions are formed at the surfaces of the cell active regions 37 c under the second spaces.
[0036] Referring to FIG. 1, a peripheral circuit gate electrode G extends across the peripheral circuit active region 37 p. Also, as shown in FIG. 12A, the peripheral circuit gate electrode G includes a lower gate electrode 15 h, a first upper gate electrode 41 h and a second upper gate electrode 51 h, which are sequentially stacked. A gate insulating layer 11 b is disposed between the peripheral circuit gate electrode G and the peripheral circuit active region 37 p. The gate insulating layer 11 b may be a high voltage gate insulating layer or a low voltage gate insulating layer.
[0037] LDD-type source/drain regions are formed at the peripheral circuit active region 37 p. The LDD-type source/drain regions are formed on both sides of the peripheral circuit gate electrode G. Each of the LDD-type source/drain regions includes a low concentration source/drain region 61 adjacent the peripheral circuit gate electrode G and a high concentration source/drain region 69 adjacent the low concentration source/drain region 61 .
[0038] A stress buffer oxide layer 63 may be interposed between the recessed spacer layer patterns 65 a and the common source regions 55 . The stress buffer oxide layer 63 preferably covers the stacked gate patterns 52 a, the drain regions 57 , the device isolation layers 39 a and 39 b, the LDD-type source/drain regions, and the peripheral circuit gate electrode G. The stress buffer oxide layer 63 alleviates physical stresses applied to the recessed spacer layer patterns 65 a.
[0039] Further, the surface of the semiconductor substrate having the recessed spacer layer patterns 65 a is covered with a conformal etching stop layer 71 (FIG. 14A). The conformal etching stop layer 71 is covered with an interlayer insulating layer 73 . It is preferable that the conformal etching stop layer 71 is an insulating layer having an etch selectivity with respect to the interlayer insulating layer 73 . For example, the etching stop layer 71 may be a silicon nitride layer. In this case, the stress buffer oxide layer 63 is located under the etching stop layer 71 and the recessed spacer layer patterns 65 a.
[0040] The LDD-type source/drain regions and the peripheral circuit gate electrode G are exposed by first contact holes 75 that penetrate the interlayer insulating layer 73 and the etching stop layer 71 . Also, the drain regions 57 are exposed by second contact holes 77 that penetrate the interlayer insulating layer 73 and the etching stop layer 71 . Plug ion implantation regions 78 may be additionally formed in the drain regions 57 . The plug ion implantation regions 78 are self-aligned with the second contact holes 77 . The first and second contact holes 75 and 77 are filled with first and second contact plugs 79 a and 79 b respectively. Metal interconnection lines 81 a and 81 b covering the first and second contact plugs 79 a and 79 b are disposed on the interlayer insulating layer 73 .
[0041] Methods for manufacturing the flash memory devices according to an embodiment of the present invention will be described.
[0042] [0042]FIGS. 2A to 14 A are sectional views taken along line I-I′ of FIG. 1, and FIGS. 2B to 14 B are sectional views taken along line II-II′ of FIG. 1. Also, FIGS. 2C to 14 C are sectional views taken along line III-III′ of FIG. 1, and FIGS. 2D to 14 D are sectional views taken along line IV-IV′ of FIG. 1.
[0043] Referring to FIGS. 1, 2A, 2 B, 2 C and 2 D, a semiconductor substrate 1 such as a P-type silicon wafer is prepared. The semiconductor substrate 1 includes a cell array region A and a peripheral circuit region B. The peripheral circuit region B may be a high voltage MOS transistor region or a low voltage MOS transistor region. In this embodiment, for simplicity, it is assumed that the peripheral circuit region B is an NMOS transistor region. A gate insulating layer 11 and a lower gate conductive layer 15 are sequentially formed on the semiconductor substrate 1 . The lower gate conductive layer 15 may be a doped polysilicon layer. The lower gate conductive layer 15 and the gate insulating layer 11 are patterned to expose the semiconductor substrate 1 in the cell array region A. A tunnel insulating layer 19 and a lower floating gate layer 21 are sequentially formed on the exposed semiconductor substrate 1 . The tunnel insulating layer 19 may comprises a thermal oxide layer. The lower floating gate layer 21 may comprises a doped polysilicon layer.
[0044] Referring to FIGS. 1, 3A, 3 B, 3 C and 3 D, a polishing stop layer and a hard mask layer are sequentially formed on a surface of the semiconductor substrate 1 having the lower floating gate layer 21 and the lower gate conductive layer 15 . The polishing stop layer and the hard mask layer are preferably formed of a silicon nitride layer and a chemical vapor deposition (CVD) oxide layer, respectively. A buffer oxide layer can be additionally formed prior to formation of the polishing stop layer. The buffer oxide layer acts as a stress buffer layer for alleviating physical stresses resulting from the polishing stop layer.
[0045] As shown in 3 A, the hard mask layer, the polishing stop layer, the buffer oxide layer, the lower floating gate layer 21 , the lower gate conductive layer, the tunnel oxide layer 19 , and the gate insulating layer 11 are patterned to form first and second trench mask patterns 33 a and 33 b in the cell array region A and the peripheral circuit region B, respectively. As a result, each of the first trench mask patterns 33 a includes a tunnel insulating layer pattern such as a tunnel oxide layer pattern 19 a, a lower floating gate pattern 21 a, a buffer oxide layer pattern 27 a, a polishing stop layer pattern 29 a, and a hard mask pattern 31 a, which are sequentially stacked, and the second trench mask pattern 33 b includes a gate insulating layer pattern 11 b, a lower gate conductive layer pattern 15 b, a buffer oxide layer pattern 27 b, a polishing stop layer pattern 29 b, and a hard mask pattern 31 b, which are sequentially stacked.
[0046] Referring to FIGS. 1, 4A, 4 B, 4 C and 4 D, a photoresist pattern 35 covering the cell array region A is formed. The semiconductor substrate 1 is etched using the photoresist pattern 35 and the second trench mask pattern 33 b as etch masks, thereby forming a preliminary peripheral circuit trench region 37 a in the peripheral circuit region B. The photoresist pattern 35 is then removed.
[0047] Referring to FIGS. 1, 5A, 5 B, 5 C and 5 D, the semiconductor substrate 1 is again etched using the first and second trench mask patterns 33 a and 33 b as etch masks. As a result, a peripheral circuit trench region 37 a′, which is deeper than the preliminary peripheral circuit trench region 37 a, is formed in the peripheral circuit region B, and a cell trench region 37 b, which is shallower than the peripheral circuit trench region 37 a′, is formed in the cell array region A. The cell trench region 37 b defines cell active regions 37 c in the cell array region A, and the peripheral circuit trench region 37 a′ defines a peripheral circuit active region 37 p in the peripheral circuit region B.
[0048] The peripheral circuit trench region 37 a′ is preferably formed to have a sufficient depth suitable for improving device isolation characteristics of a peripheral circuit MOS transistor to be formed in subsequent processes. On the contrary, the cell trench region 37 b should have a shallow depth suitable for formation of a common source region to be formed in subsequent processes. As a result, it is preferable that the peripheral circuit trench region 37 a′ is deeper than the cell trench region 3 7 b.
[0049] However, the trench regions 37 a′ and 37 b may be formed using a single step of etching process without use of the photoresist pattern 35 shown in FIGS. 4A, 4B, 4 C and 4 D. In this case, the cell trench region 37 b has the same depth as the peripheral circuit trench region 37 a′.
[0050] Referring to FIGS. 1, 6A, 6 B, 6 C and 6 D, a cell device isolation layer 39 b and a peripheral circuit device isolation layer 39 a are respectively formed in the cell trench region 37 b and the peripheral circuit trench region 37 a′ using a conventional method. The hard mask patterns 31 a and 31 b are removed during formation of the device isolation layers 39 a and 39 b, thereby exposing the polishing stop layer patterns 29 a and 29 b. Preferably, the device isolation layers 39 a and 39 b are recessed as shown in FIGS. 6A, 6B, 6 C and 6 D to have substantially the same height as the top surfaces of the lower floating gate patterns 21 a.
[0051] Referring to FIGS. 1, 7A, 7 B, 7 C and 7 D, the polishing stop layer patterns 29 a and 29 b and the buffer oxide layer patterns 27 a and 27 b are removed to expose the lower floating gate patterns 21 a and the lower gate conductive layer pattern 15 b. A first conductive layer is formed on the semiconductor substrate 1 where the polishing stop layer patterns 29 a and 29 b as well as the buffer oxide layer patterns 27 a and 27 b are removed. The second conductive layer preferably may include a doped polysilicon layer. The second conductive layer is patterned to form upper floating gate patterns 41 a covering the lower floating gate patterns 21 a and concurrently form a first upper gate conductive layer 41 b covering the peripheral circuit region B. The upper floating gate patterns 41 a are preferably formed to be wider than the lower floating gate patterns 21 a.
[0052] Subsequently, an inter-gate dielectric layer 47 and a second conductive layer 49 are sequentially formed on the semiconductor substrate having the upper floating gate patterns 41 a and the first upper gate conductive layer 41 b. The second conductive layer 49 may include a doped polysilicon layer.
[0053] Referring to FIGS. 1, 8A, 8 B, 8 C and 8 D, the second conductive layer 49 and the inter-gate dielectric layer 47 are patterned to expose the first upper gate conductive layer 41 b in the peripheral circuit region B. As a result, a first control gate conductive layer 49 a is formed in the cell array region A, and the inter-gate dielectric layer 47 is remained under the first control gate conductive layer 49 a. A third conductive layer 51 is formed on the semiconductor substrate having the first control gate conductive layer 49 a. The third conductive layer 51 preferably includes a material layer that has a lower resistivity than the doped polysilicon layer. For example, the third conductive layer 51 may be formed of a metal silicide layer such as a tungsten silicide layer. The third conductive layer 51 on the cell array region A corresponds to a second control gate conductive layer, and the third conductive layer 51 on the peripheral circuit region B corresponds to a second upper gate conductive layer. The process for forming the third conductive layer 51 is omitted for simplicity.
[0054] In the cell array region A, the lower floating gate patterns 21 a, the upper floating gate patterns 41 a, the inter-gate dielectric layer 47 , the first control gate conductive layer 49 a and the second control gate conductive layer 51 constitute a stacked gate layer. Also, in the peripheral circuit region B, the first and second upper gate conductive layers 41 b and 51 as well as the lower gate conductive layer pattern 15 b constitute a peripheral circuit gate layer.
[0055] Referring to FIGS. 1, 9A, 9 B, 9 C and 9 D, the stacked gate layer is patterned to form a plurality of first gate patterns 52 a, e.g., stacked gate patterns that extend across the cell active regions 37 c in the cell array region A. As a result, each of the stacked gate patterns 52 a includes a tunnel insulating layer such as a tunnel oxide layer pattern 19 a, a floating gate FG, an inter-gate dielectric layer 47 and a control gate electrode CG, which are sequentially stacked.
[0056] As shown in FIG. 1, the floating gates FG are formed at the intersections of the control gate electrodes CG and the cell active regions 37 c. In other words, the floating gates FG are disposed between the control gate electrodes CG and the cell active regions 37 c. On the contrary, the control gate electrodes CG extend across the cell active regions 37 c as well as the cell device isolation layer 39 b between the cell active regions 37 c. Each of the floating gates FG includes a lower floating gate 21 f and an upper floating gate 41 f, which are sequentially stacked, and each of the control gate electrodes CG includes a first control gate electrode 49 c and a second control gate electrode 51 c, which are sequentially stacked.
[0057] The regions between the stacked gate patterns 52 a include first spaces SO and second spaces DO. The first spaces SO have a first width S1, and the second spaces DO have a second width S2 greater than the first width S1. A photoresist pattern 53 is formed on the semiconductor substrate having the stacked gate patterns 52 a. The photoresist pattern 53 is formed to cover the second spaces DO as well as the peripheral circuit region B. In other words, the photoresist pattern 53 is formed to selectively expose the first spaces SO.
[0058] Referring to FIGS. 1, 10A, 10 B, 10 C and 10 D, the cell device isolation layer 39 b is selectively etched using the photoresist pattern 53 as an etch mask. As a result, as shown in FIG. 10B, the cell trench region 37 b is again formed between the cell active regions 37 c in the first spaces SO. That is, the bottom surfaces of the first spaces SO exhibit uneven and stepped profiles in the direction across the cell active regions 37 c.
[0059] N-type impurity ions are implanted into the semiconductor substrate using the photoresist pattern 53 as an ion implantation mask. As a result, first impurity regions 55 , e.g., common source regions having line shapes are formed at the surface of the semiconductor substrate exposed by the first spaces SO. In this case, the ion implantation process is preferably performed using a tilted ion implantation process in order to reduce electrical resistance of the common source regions 55 formed at side walls of the cell trench regions in the first spaces SO. In addition, the trench region 37 b is preferably shallow to reduce the electrical resistance of the common source regions 55 as described in FIGS. 9A to 9 D.
[0060] Subsequently, after removing the photoresist pattern 53 , N-type impurity ions are selectively implanted into the first and second spaces SO and DO using the stacked gate patterns 52 a, the upper gate conductive layers 41 b and 51 b, and the cell device isolation layer 39 b as ion implantation masks. As a result, island-shaped second impurity regions 57 , e.g., drain regions are formed at the surfaces of the cell active regions 37 c exposed by the second spaces DO. During the ion implantation process for forming the drain regions 57 , the N-type impurity ions are additionally implanted into the common source regions 55 . Therefore, the impurity concentration of the common source regions 55 is more increased to reduce the electrical resistance of the common source regions 55 .
[0061] The ion implantation process for forming the common source regions 55 may be omitted prior to removal of the photoresist pattern 53 . In this case, the common source regions 55 and the drain regions 57 are concurrently formed using only a single step ion implantation process.
[0062] Referring to FIGS. 1, 11A, 11 B, 11 C and 11 D, the peripheral circuit gate layer is patterned to form a second gate pattern G, e.g., a peripheral circuit gate electrode in the peripheral circuit region B. The peripheral circuit gate electrode G extends across the peripheral circuit active region 37 p. The peripheral circuit gate electrode G includes a lower gate electrode 15 h, a first upper gate electrode 41 h and a second upper gate electrode 51 h, which are sequentially stacked.
[0063] N-type impurity ions 59 are implanted into the active regions 37 c and 37 p at a low dose of 1×1012 atoms/cm 2 to 1×1014 atoms/cm 2 using the stacked gate patterns 52 a, the peripheral circuit gate electrode G, and the device isolation layers 39 a and 39 b as ion implantation masks. As a result, low concentration source/drain regions 61 are formed at the peripheral circuit active region 37 p.
[0064] Referring to FIGS. 1, 12A, 12 B, 12 C and 12 D, a spacer layer is formed on the semiconductor substrate having the low concentration source/drain regions 61 . The spacer layer may include an insulating layer having an etching selectivity with respect to a silicon oxide layer. For example, the spacer layer may include a silicon nitride layer. Also, the spacer layer is formed to a thickness that is greater than half of the first width S1 and less than half of the second width S2. Therefore, the first spaces SO are filled with the spacer layer. A stress buffer oxide layer 63 is preferably formed on the semiconductor substrate 1 having the low concentration source/drain regions 61 prior to formation of the spacer layer. The stress buffer oxide layer 63 is formed in order to alleviate the stress applied to the spacer layer. The stress buffer oxide layer 63 may be formed of a CVD oxide layer such as a medium temperature oxide (MTO) layer. Further, the stress buffer oxide layer 63 is preferably formed to a thin thickness of about 200 angstroms.
[0065] As shown in FIG. 12, the spacer layer is anisotropically etched to form spacers 65 on sidewalls of the second spaces DO and on sidewalls of the peripheral circuit gate electrode G. In this case, the first spaces SO are still filled with the anisotropically etched spacer layer patterns 65 ′. In other words, the stress buffer oxide layer 63 on the common source regions 55 is still covered with the spacer layer patterns 65 ′ even after the spacers 65 are formed. On the other hand, the stress buffer oxide layers 63 on the drain regions 57 and the low concentration source/drain regions 61 are exposed after the spacers 65 are formed.
[0066] If the spacer layer is over-etched, the drain regions 57 and the low concentration source/drain regions 61 may be exposed. Nevertheless, the spacer layer patterns 65 ′ on the common source regions 55 have a different configuration from the spacers 65 and are not easily removed.
[0067] A photoresist pattern 67 covering the cell array region A is then formed. Using the photoresist pattern 67 , the peripheral circuit gate electrode G, the spacers 65 and the peripheral circuit device isolation layer 39 a as ion implantation masks, N-type impurity ions are implanted into the peripheral circuit active region 37 p at a high dose of 1 ×1015 atoms/cm 2 to 5×1015 atoms/cm 2 , thereby forming high concentration source/drain regions 69 adjacent the low concentration source/drain regions 61 . As a result, LDD-type source/drain regions including the low concentration source/drain regions 61 and the high concentration source/drain regions 69 are formed in the peripheral circuit region B. Each of the second spaces DO has a third width S3, which is less than the second width (S2 of FIGS. 14A and 1) because of the spacers 65 .
[0068] Referring to FIGS. 1, 13A, 13 B, 13 C and 13 D, the photoresist pattern 67 is removed. In general, the spacers 65 are used in formation of the LDD-type source/drain regions as described above. Therefore, it is preferable that the spacers 65 are removed after formation of the LDD-type source/drain regions. This is because the spacers 65 may cause problems in subsequent processing steps. For example, when the spacers 65 exist, there is a limitation in increasing the widths of contact holes to be formed in order to expose the drain regions 57 and the LDD-type source/drain regions in subsequent processes. On the contrary, it is preferable that the spacer layer patterns 65 ′ in the first spaces SO are not removed. This is because when the spacer layer patterns 65 ′ are removed the aspect ratio of the first spaces SO is greatly increased to generate voids in the first spaces SO during formation of an interlayer insulating layer in subsequent processes. These voids may cause unstable electrical characteristics in flash memory cells.
[0069] As a result, it is preferable that the spacers 65 are removed using a wet etching process. The wet etching process may be performed using a phosphoric acid (H 3 PO 4 ). The spacer layer patterns 65 ′ should not be removed during the wet etching process. Therefore, the wet etching process should be performed for a proper duration. As a result, recessed spacer layer patterns 65 a remain in the first spaces SO.
[0070] Preferably, an etching stop layer 71 is formed on the semiconductor substrate 1 having the recessed spacer layer patterns 65 a. The etching stop layer 71 is formed to a thickness, which is less than the width of the spacers 65 . Thus, the second spaces DO have a fourth width S4 that is greater than the third width S3. The etching stop layer 71 may be formed of an insulating layer that has an etching selectivity with respect to a conventional interlayer insulating layer. For example, the etching stop layer 71 may include a silicon nitride layer. An interlayer insulating layer 73 is formed on the etching stop layer 71 . In this case, voids can be prevented from being formed in the first spaces SO because of the presence of the recessed spacer layer patterns 65 a.
[0071] Referring to FIGS. 1, 14A, 14 B, 14 C and 14 D, the interlayer insulating layer 73 , the etching stop layer 71 and the stress buffer oxide layer 63 are patterned to form first contact holes 75 that expose the LDD-type source/drain regions in the peripheral circuit region B. The peripheral circuit gate electrode G may be also exposed during formation of the first contact holes 75 . Then, the interlayer insulating layer 73 , the etching stop layer 71 and the stress buffer oxide layer 63 are again patterned to form second contact holes 77 that expose the drain regions 57 . Removal of the spacers 65 may lead to maximization of widths of the first and second contact holes 75 and 77 . As a result, it is possible to reduce contact resistance.
[0072] Furthermore, N-type impurity ions may be additionally implanted into the drain regions 57 through the second contact holes 77 . As a result, plug ion implantation regions 78 , which are self-aligned with the second contact holes 77 , are formed in the drain regions 57 . The plug ion implantation regions 78 lead to a reduction in the contact resistance of the drain regions 57 and prevent the junction spiking phenomenon from being occurred in the drain regions 57 .
[0073] Alternatively, the first contact holes 75 and the second contact holes 77 can be concurrently formed using a single step of an etching process.
[0074] Subsequently, first and second contact plugs 79 a and 79 b are respectively formed in the first and second contact holes 75 and 77 using a conventional method. The contact plugs 79 a and 79 b are formed of a tungsten layer.
[0075] A metal layer such as an aluminum layer is formed on the interlayer insulating layer 73 . The metal layer is patterned to form first metal interconnection lines 81 a and second metal interconnection lines 81 b in the peripheral circuit region B and the cell array region A, respectively. The second metal interconnection lines 81 b extend across the control gate electrodes CG and acts as bit lines of flash memory cells. The bit lines 81 b are electrically connected to the drain regions 57 through the second contact plugs 79 b. The first and second metal interconnection lines 81 a and 81 b may be formed using a conventional damascene process that employs a metal layer such as a copper layer.
[0076] According to the present invention as described above, narrow spaces of the regions between the stacked gate patterns are filled with recessed spacer layer patterns, whereas spacers formed on sidewalls of the stacked gate patterns and the peripheral circuit gate electrode are removed after formation of LDD-type source/drain regions in the peripheral circuit region. Accordingly, it is possible to maximize widths of contact holes that expose the source/drain regions, and it can prevent voids from being formed in the narrow spaces. As a result, reliable and highly-integrated flash memory devices can be realized.
[0077] While the present invention has been particularly shown and described with reference to the exemplary embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the present invention.
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Methods of manufacturing a semiconductor integrated circuit using selective disposable spacer technology and semiconductor integrated circuits manufactured thereby: The method includes forming a plurality of gate patterns on a semiconductor substrate. Gap regions between the gate patterns include first spaces having a first width and second spaces having a second width greater than the first width. Spacers are formed on sidewalls of the second spaces, and spacer layer patterns filling the first spaces are also formed together with the spacers. The spacers are selectively removed to expose the sidewalls of the first spaces. As a result, the semiconductor integrated circuit includes wide spaces enlarged by the removal of the spacers and narrow and deep spaces filled with the spacer layer patterns.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/463,748, filed on Aug. 20, 2014, incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to the field of engineering physics, and, in particular, to X-ray scanning for harmful objects or substances located on a human body or hidden in body cavities in order to prevent theft or terrorist acts in buildings, airports, malls, train station, subways and other public places.
[0004] 2. Description of the Related Art
[0005] Human body X-ray scanning for identifying some highly undesirable objects or substances has become critically important in view of terrorist threats. Security applications may include prevention of smuggling of drugs, precious stones and metals, as well as provision of the security at airports, banks, embassies, nuclear power centers and other high-risk locations. X-ray luggage examination in airports is currently the most efficient way to provide the security of the flights. X-ray examination is also used in prisons for visitor's access control.
[0006] X-ray luggage examination systems are designed as a conveyer passing through a rectangular frame with an X-ray source installed in the upper part of the frame and a detector of X-radiation installed in the lower part of the frame under the conveyor. However, the described system is not designed for scanning of the passengers due to high level of radiation emitted by an X-ray source, which is used to increase the resolution of the images.
[0007] Scanning of passengers for presence of metallic objects hidden under clothing is provided with the help of electromagnetic frames and metal detectors. An X-ray method has not been used until recently for the examination due to its harmful effects on people, especially in cases of frequent use. A number of efforts have been attempted lately to use a low-dose X-ray scanning, which could be applied to examination of people without any threat to their health. One of these systems is X-ray scanning apparatus named Body Search produces by American Science and Engineering, Inc.
[0008] A person is scanned with a beam of X-radiation of sufficiently low intensity, while the radiation transmitted through the person's body is converted into an image, which is used to determine the presence of concealed objects. The Body Search system includes housing with an X-ray source of low-intensity, means for shaping an X-ray beam and a detector of X-radiation transmitted through the clothing and reflected by the body. The reflected X-radiation is detected by the detector to generate an image of the objects located on the surface of the body, in the clothing or on the clothing of the portion of the body turned towards the housing with X-ray source.
[0009] For full examination it is necessary to make scanning in two positions—i.e., the face towards the housing and the back towards the housing. With this method the internal cavities of the body that are very often used for concealment of drugs and precious stones are not subjected to the examination. Besides, the strongest radiation effects the most sensitive human organs located in the medium portion of the body, while the person's feet and especially shoes that may be used for concealing the contraband are out of the view of the examiner.
[0010] Conventional stationary examinations stations employ a single source of low-intensity X-ray radiation. An integrated collimator and a detector of X-ray radiation passed through the body of the person being examined are used. The system also includes a data processing module and a platform for supporting the person being examined. The disadvantage of this system is its stationary nature—it is hard to relocate and calibrate this scanner. Also, such scanners show poor performance for many objects hidden inside body cavities, depending on the angle of orientation of the object and the X-ray beam.
[0011] The mobility issue is addressed by an X-ray scanner located in the back of a truck (see EP2458408). An operator workplace and an X-ray scanner system are located in the back of the truck. The system includes a source of X-ray radiation with at least one slit collimator located approximately at a person's navel level. The system also includes a linear detector of X-ray radiation that has passed through the body of the person being examined. The X-ray compartment has two vertical columns with a platform that moves laterally between the columns.
[0012] However, the most sensitive body organs located in the middle portion of the body are exposed to the radiation, while legs and, especially, shoes (often used for smuggling objects) are not fully examined by the scanner. Furthermore, the system cannot scan the person's body in a single cycle. Several scans are needed, which reduces the efficiency of the system, because the person has to step onto the platform and remain still during the scan.
[0013] Accordingly, there is a need in the art for a safe mobile X-ray scanner system that provides for a complete X-ray scan of person with a high accuracy and improved efficiency.
SUMMARY OF THE INVENTION
[0014] Accordingly, the present invention is related to a high-efficiency multi-beam stereoscopic X-ray scanner that substantially obviates one or more of the disadvantages of the related art.
[0015] In one aspect of the invention, a module for processing and visualization of digital signals and an X-ray module are located in a back of a van. The digital X-ray module includes two sources of low-intensity X-ray radiation with at least one slit collimator and a linear detector of X-ray radiation passing through the body of the person being examined. The X-ray module has two vertical columns and a mobile platform located between these columns for supporting and moving the person being examined. (As an alternative, a conveyor-belt type transporter can be used.)
[0016] The columns are located along the vertical axis of the body of the van, while the platform moves in a horizontal plane across the body of the van between the columns. The detector of the X-ray radiation is located along the entire length of one of the columns. The slit collimator is integrated in the second column. The collimator is rigidly connected to the source of radiation located on a special platform located near the outer surface of the second column.
[0017] The source of the radiation is located on a special platform and can move along a vertical axis. The second column has rails for vertical movement of the slit collimator. The platform with the source of the radiation at its most low position creates a horizontal plane passing through the bottom of the person's body dissects a pre-set number of degrees from the radiation rays. The radiation source platform can be moved in a vertical plane by a hydraulic lift.
[0018] Additional features and advantages of the invention will be set forth in the description that follows, and in part will be apparent from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0019] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE ATTACHED FIGURES
[0020] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0021] In the drawings:
[0022] FIGS. 1A-1C illustrate the exemplary X-ray scanning system;
[0023] FIG. 2 illustrates a top view of the X-ray system, in accordance with the exemplary embodiment;
[0024] FIG. 3 illustrates a side view of the X-ray system;
[0025] FIGS. 4-5 illustrate a system assembly shown from different angles;
[0026] FIGS. 6-11 illustrate exemplary images produced by the X-ray system.
[0027] FIG. 12 illustrates an exemplary mobile X-ray device, in accordance with the exemplary embodiment;
[0028] FIG. 13 illustrates a top view of the mobile X-ray system;
[0029] FIG. 14 illustrates a back view of the X-ray system located inside a van;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0031] In one aspect of the invention, a module for processing and visualization of digital signals and one or more X-ray modules are either stationary or located in a back of a van or a truck. The digital X-ray module includes two sources of X-ray radiation. Each of the X-ray sources has one slit collimator to produce a fan beam, and one a linear detector of X-ray radiation passing through the body of the person being examined. The fan beams may be located in parallel planes, or the planes in which the fan beams are located may be angled relative to each other (e.g., by several degrees, up to 10-20 degrees). The X-ray module has at least two vertical columns and a mobile platform located between these columns for placing the person being examined.
[0032] The columns are located along the vertical axis of the body of the van, while the platform moves in a horizontal plane across the floor or the body of the van. A first detector of the X-ray radiation is located along the entire length of the first column, and optionally in a horizontal section of the overhead frame. One of the slit collimators is integrated in the second column. The collimator is rigidly connected to the source of radiation located on a special platform located near the outer surface of the second column.
[0033] One of the X-ray sources can move along a vertical axis using a hydraulic mechanism, or can rotate, so as to aim the fan-shaped X-ray beam at different portions of the body. Note that the beam needs to remain on the detector as the X-ray source moves or rotates. The second X-ray source's fan beam lowermost edge is aimed 2-5 degrees downward from the horizontal in order to scan a person's shoes.
[0034] In the mobile embodiment, horizontal rails are implemented on the floor of the van for allowing the person carrying platform to move across between the vertical columns. According to an exemplary embodiment, the platform can move from one side door of the van to the opposite side door. The X-ray module is separated from the driver area by at least one X-ray protective screen.
[0035] FIGS. 1A-1C illustrate the exemplary X-ray scanner 101 in more detail. Two vertical columns 102 and 105 are either standalone or attached to the floor of the van 1200 (see FIG. 12 ) along the longitudinal axis of the body of the van. A platform 114 moves in a horizontal plane across the floor or the body of the van. A linear detector of the X-ray radiation 122 is located along the entire length of one of the column 105 and covered by the housing 110 . Another L-shaped linear detector 120 is located at the top upper corner adjacent to the column 105 and extending along the entire height of the scanner. A slit collimator is integrated in the second column 105 and covered by the housing 116 . The collimator is rigidly connected to the sources of radiation 106 and 108 .
[0036] The source of the radiation 106 is located on a special platform that can move along a vertical axis in order to scan the upper body of a person. The second column 105 has rails for vertical movement of the slit collimator 122 . The second source of radiation 118 is located on a platform at floor level and can scan the lower body of a person.
[0037] The platform with the source of the radiation 118 creates a horizontal plane passing through the bottom of the person's body dissects 2-5 degrees from the radiation rays. The radiation source 106 platform can be moved in a vertical plane by a hydraulic lift in order to accommodate people of different sizes. Alternatively, angular positioning of the radiation source 106 can be changed.
[0038] A movable platform 112 for supporting a person being examined moves across the floor or across the body of the van 1200 along rails 114 . The platform 112 has an integrated motor. The columns 105 and 102 are connected by a top bar 107 equipped with a signaling light 104 , which indicates that the X-ray radiation is on. Both of the X-ray sources 106 and 118 can turn on simultaneously so the person's body is scanned in a single cycle from the head to the bottoms of the shoes and pseudo-stereoscopic images are generated. Alternatively, the broader (whole body) scan from X-ray source 108 can be performed first, and then a scan of the person's midsection using X-ray source 106 can be performed if necessary.
[0039] A person subject to examination enters the van from a side door and step onto the platform 114 powered by an electric motor. The platform 112 moves between the columns 102 and 105 on rails 114 . Thus, the person’ body crosses the X-rays coming from the X-ray sources 106 and 118 . The X-rays passing through the body of the person at any moment are received by linear detectors 120 and 122 that convert received X-ray signal into digital signals. Not that the detector 120 consists of two linear detectors. In one embodiment, multi-energy detectors can be used for better recognition of the hidden objects. For example, a detector can process signals of 160 KV, 120 KV, 80 KV and 60 KV. This allows to recognize objects of organic nature (e.g., narcotics) hidden in the human body. The organic substance (such as narcotics) has an atomic mass similar to the human body, and signals of different energy produce better X-ray images, allowing for precise recognition of the organic objects inside a human body or hidden under clothing.
[0040] The digital signals are passed on to operator work station 1210 (see FIG. 12 ). Then, the person steps off the platform 114 and exits the van through another side door. The X-ray sources 106 and 118 have focal points F 1 and F 2 respectively. The two focal areas, advantageously, provide for scanning of the entire body of the person in a latitudinal plane so any objects located inside the body are detected and not screened by the bones as may happened in case of scan with only one X-ray source. Note that the X-ray source 106 can be moved inside the housing 116 in order to get a more detailed view of a suspected area (e.g., chest or abdominal area). The exemplary embodiment produces a very low dose of radiation in any mode of operation. This allows for safe scanning of passengers, customers or spectators. The X-ray sources are placed into protective housing 108 and 116 respectively.
[0041] Note that the X-ray source 108 is less powerful (in unlimited range of radiation up to 0.25 microSieverts) than the source 106 . In one embodiment, only the unlimited X-ray source 108 is used for most of the people being examined and the second more powerful (limited range of radiation—normally up to 2 microSieverts, with up to 10 microSieverts as permitted under ANSI standards) X-ray source 106 is used in case of suspicion that the person is hiding something inside his body. The X-ray sources may be operated simultaneously, or in sequence (e.g., source 106 first, then source 108 , or vice versa), as selected by the operator.
[0042] FIG. 2 illustrates a top view of the X-ray scanning system 101 , in accordance with the exemplary embodiment. Units 211 and 210 represent ventilation covers mounted into the housing 116 . An optional motor or a hydraulic mechanism for moving or rotating the radiation source 106 is located in housing 215 . The radiation source can be repositioned or rotated to accommodate people of different sizes or heights.
[0043] FIG. 3 illustrates a side view. Element 310 is a power outlet used for powering the X-ray scanning system 101 . FIGS. 4-5 illustrate a system assembly shown from different angles.
[0044] FIG. 6 illustrates an image produced by the high-intensity X-ray source depicting a razor blade hidden inside the body. FIG. 7 illustrates an image produced by the low-intensity X-rays source. This image indicates presence of a foreign object inside the body, but does not show the actual razor blade. FIG. 8 illustrates zoomed images showing the razor blade hidden inside person's colon. FIGS. 9 and 10 illustrate images of drugs hidden inside person's stomach. FIG. 11 illustrates zoomed-in images showing the hidden drugs (see circled areas).
[0045] An exemplary mobile X-ray scanning system is depicted in FIG. 12 . The X-ray scanning system 101 is positioned inside the body of a van 1200 . A module for processing and visualization of digital signals (not shown), operator work place 1210 and the X-ray scanning system 101 are located in a back of the van 1200 as shown in FIG. 13 depicting a top view of the van 1200 .
[0046] FIG. 13 illustrates a back view of the X-ray system 101 , which may be stationary or located inside the van 1200 (see FIG. 12 ).
[0047] FIG. 14 illustrates a top view of the mobile X-ray system 101 .
[0048] Having thus described a preferred embodiment, it should be apparent to those skilled in the art that certain advantages of the described method and apparatus have been achieved.
[0049] It should also be appreciated that various modifications, adaptations, and alternative embodiments thereof may be made within the scope and spirit of the present invention. The invention is further defined by the following claims.
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An X-ray examination station includes a first source of X-ray radiation for whole body scanning of a human body using a first fan beam of X-ray radiation; a first vertical linear radiation detector configured to detect the first fan beam; a second source of X-ray radiation installed at mid-height of a person being examined, for scanning a central portion of the human body using a second fan beam of X-ray radiation; a second vertical detector of X-ray radiation configured to detect the second fan beam; and a control unit configured to turn on each of the X-ray radiation sources. The first and the second radiation fan beams are emitted in parallel planes. The first X-ray radiation source is turned on for the whole body scanning. The second X-ray radiation source is turned on for scanning the central portion of the body.
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BACKGROUND
The present invention relates generally to semiconductor device manufacturing and, more particularly, to a strained, thin body transistor device having vertically raised source/drain stressors with a single spacer.
Semiconductor-on-insulator (SOI) devices, such as silicon-on-insulator devices, offer several advantages over more conventional semiconductor devices. For example, SOI devices may have lower power consumption requirements than other types of devices that perform similar tasks. SOI devices may also have lower parasitic capacitances than non-SOI devices. This translates into faster switching times for the resulting circuits. In addition, the phenomenon of latchup, which is often exhibited by complementary metal-oxide semiconductor (CMOS) devices, may be avoided when circuit devices are manufactured using SOI fabrication processes. SOI devices are also less susceptible to the adverse effects of ionizing radiation and, therefore, tend to be more reliable in applications where ionizing radiation may cause operation errors.
The gain of a MOS transistor, usually defined by the transconductance (g m ), is proportional to the mobility (μ) of the majority carrier in the transistor channel. The current carrying capability, and hence the performance of an MOS transistor is proportional to the mobility of the majority carrier in the channel. The mobility of holes, which are the majority carriers in a P-channel field effect (PFET) transistor, and the mobility of electrons, which are the majority carriers in an N-channel field effect (NFET) transistor, may be enhanced by applying an appropriate stress to the channel. Existing stress engineering methods greatly enhance circuit performance by increasing device drive current without increasing device size and device capacitance. For example, a tensile stress liner applied to an NFET transistor induces a longitudinal stress in the channel and enhances the electron mobility, while a compressive stress liner applied to a PFET transistor induces a compressive stress in the channel and enhances the hole mobility.
There are several process integration methods for the creation of dual stress films. The underlying theme is the blanket deposition of a first stress layer type, followed by lithography to mask and protect this first stress layer type, an etch to remove the first stress layer type where it is not desired, and then deposition of the second stress layer type. The resulting enhanced carrier mobility, in turn, leads to higher drive currents and therefore higher circuit level performance.
Ultrathin body silicon MOSFETs, such as ETSOI (extremely thin SOI) or FinFETs, are considered viable options for CMOS scaling for the 22 nanometer (nm) node and beyond. However, a thin-body SOI transistor such an ETSOI transistor needs epitaxially grown, raised source/drain regions to achieve a sufficiently low transistor series resistance. Moreover, due to the extreme thinness of the ETSOI layer (e.g., on the order of about 6 nm), embedded source/drain stressors are not a viable means of inducing channel stress, as the trenches used to form embedded stressors are conventionally about 60-80 nm deep into the SOI layer. Consequently, it is a significant challenge to incorporate conventional stress layer techniques into such ultrathin film devices.
SUMMARY
In an exemplary embodiment, a method of forming a transistor device includes forming a patterned gate structure over a semiconductor substrate; forming a spacer layer over the semiconductor substrate and patterned gate structure; removing horizontally disposed portions of the spacer layer so as to form a vertical sidewall spacer adjacent the patterned gate structure; and forming a raised source/drain (RSD) structure over the semiconductor substrate and adjacent the vertical sidewall spacer, wherein the RSD structure has a substantially vertical sidewall profile so as to abut the vertical sidewall spacer and produce one of a compressive and a tensile strain on a channel region of the semiconductor substrate below the patterned gate structure.
In another embodiment, a method of forming a complementary metal oxide semiconductor (CMOS) device includes forming a first patterned gate structure over a semiconductor substrate corresponding to a first polarity type transistor region, and forming a second patterned gate structure over the semiconductor substrate corresponding to a second polarity type transistor region; forming a spacer layer over the semiconductor substrate and the first and patterned gate structures; removing horizontally disposed portions of the spacer layer in the first polarity type transistor region so as to form a vertical sidewall spacer adjacent the first patterned gate structure; forming a first type raised source/drain (RSD) structure over the semiconductor substrate and adjacent the vertical sidewall spacer of the first patterned gate structure, wherein the first type RSD structure has a substantially vertical sidewall profile so as to abut the vertical sidewall spacer of the first patterned gate structure and produce one of a compressive and a tensile strain on a channel region of the semiconductor substrate below the first patterned gate structure; forming a protective hardmask over first and second polarity type transistor regions; removing the protective hardmask and horizontally disposed portions of the spacer layer in the second polarity type transistor region so as to form a vertical sidewall spacer adjacent the second patterned gate structure; forming a second type raised source/drain (RSD) structure over the semiconductor substrate and adjacent the vertical sidewall spacer of the second patterned gate structure, wherein the second type RSD structure has a substantially vertical sidewall profile so as to abut the vertical sidewall spacer of the second patterned gate structure and produce the other of a compressive and a tensile strain on a channel region of the semiconductor substrate below the second patterned gate structure; and removing the protective hardmask in the first polarity type transistor region.
In another embodiment, a transistor device includes a patterned gate structure formed over a semiconductor substrate; a vertical sidewall spacer formed adjacent the patterned gate structure; and a raised source/drain (RSD) structure formed over the semiconductor substrate and adjacent the vertical sidewall spacer, wherein the RSD structure has a substantially vertical sidewall profile so as to abut the vertical sidewall spacer and produce one of a compressive and a tensile strain on a channel region of the semiconductor substrate below the patterned gate structure.
In still another embodiment, a complementary metal oxide semiconductor (CMOS) device includes a first patterned gate structure formed over a semiconductor substrate corresponding to a first polarity type transistor region, and a second patterned gate structure formed over the semiconductor substrate corresponding to a second polarity type transistor region; a vertical sidewall spacer formed adjacent the first patterned gate structure; a first type raised source/drain (RSD) structure formed over the semiconductor substrate and adjacent the vertical sidewall spacer of the first patterned gate structure, wherein the first type RSD structure has a substantially vertical sidewall profile so as to abut the vertical sidewall spacer of the first patterned gate structure and produce one of a compressive and a tensile strain on a channel region of the semiconductor substrate below the first patterned gate structure; a vertical sidewall spacer formed adjacent the second patterned gate structure; and a second type raised source/drain (RSD) structure formed over the semiconductor substrate and adjacent the vertical sidewall spacer of the second patterned gate structure, wherein the second type RSD structure has a substantially vertical sidewall profile so as to abut the vertical sidewall spacer of the second patterned gate structure and produce the other of a compressive and a tensile strain on a channel region of the semiconductor substrate below the second patterned gate structure.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Referring to the exemplary drawings wherein like elements are numbered alike in the several Figures:
FIGS. 1( a ) through 1 ( i ) are cross sectional views of an exemplary method of forming complementary ETSOI transistor devices having vertically profiled, raised source/drain stressors with a single spacer, in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
Disclosed herein is a thin body (ETSOI) transistor device having vertically profiled, raised source/drain stressors with a single spacer. Different raised source/drain (RSD) stressors are formed for the NFET and PFET devices so as to provide compressive stress for the channel of the PFET devices and tensile stress for the channel of the NFET devices. In addition, the RSDs of both the NFET and PFET devices are formed so as to abut vertical sidewalls of thin, single gate spacers, which maximize strain transfer to the channel, as well as keeps subsequent silicide contact formation a sufficient distance from the channel. The thin spacer is instrumental in forming MOSFET devices with a tight pitch and enabling reduction in the access resistance.
Referring initially to FIG. 1( a ), there is shown a cross sectional view of a CMOS device including a PFET device 102 and an NFET device 104 . A buried oxide (BOX) layer 106 (or more generally a buried insulator layer) is formed over a bulk substrate (not shown). In the embodiment depicted, an SOI layer 108 is an ETSOI layer, having an exemplary thickness on the order of about 10 nm or less, such as produced by SOI thinning. The PFET device 102 is electrically isolated from the NFET device 104 by insulating regions 110 , such as shallow trench isolations (STI) or mesas, for example.
As further illustrated in FIG. 1( a ), gate stack structures 112 a , 112 b , for both the PFET 102 and the NFET 104 are respectively formed, including a gate dielectric layer(s) 114 , gate electrode 116 , and a protective gate nitride cap 118 . The gate stack structures may include any suitable gate dielectric and gate conductor materials known in the art including, for example, high-k/metal gate (HKMG) stack materials. Further, the gate stack materials and/or doping may be the same or may be different for the PFET 102 and the NFET 104 , depending on the degree to which individual workfunctions are tailored.
In FIG. 1( b ), a spacer layer 120 is formed over both the PFET and NFET devices. The spacer layer 120 is an insulating layer such as, for example, an oxide or a nitride. In the case of a nitride, the spacer layer 120 is formed with a different process with respect to the gate nitride cap 118 , so as to result in an etch selectivity therebetween. A photoresist layer 122 is then formed over the devices, and patterned in a manner that exposes the PFET device 102 , as shown in FIG. 1( c ).
With the hardened resist in place over the NFET device 104 , the exposed spacer layer 120 over portions of the PFET device 102 is subjected to a directional etch (e.g., a reactive ion etch (RIE)) that removes horizontally oriented portions of the first spacer layer, thereby forming thin sidewall spacers 124 on the PFET gate stack structure 112 a , as further depicted in FIG. 1( c ). In FIG. 1( d ), the resist over the NFET device 104 is stripped, and PFET raised source/drain structures 126 are epitaxially grown on the ETSOI layer 108 . The raised source/drain structures 126 are of a first semiconductor type that will serve to provide a compressive stress on the PFET channel. In an exemplary embodiment, the raised source/drain structures 126 comprise silicon germanium (SiGe).
Because of the small thickness of the ETSOI layer 108 , the SiGe formation is also in-situ doped with a suitable p-type dopant material, such as boron (B) for example. In so doing, a conventional dopant ion implant process may be avoided, which may otherwise damage the crystal structure of the ETSOI layer 108 by creating amorphous regions therein and relaxing the strain in the SiGe and Si:C layers. As will also be noted from FIG. 1( d ), instead of a faceted or angled RSD sidewall profile, the SiGe RSD structures 126 have sidewalls that vertically abut the thin spacers 124 which, as will be illustrated below, keeps silicide contact formation away from the channel region without the need for forming a second (and consequently thicker) spacer. Moreover, the vertically profiled SiGe RSD structures 126 enhance the compressive stress provided to the channel, in comparison to a faceted profile.
Referring now to FIG. 1( e ), a hardmask layer 128 is formed over both the PFET and NFET devices. The hardmask layer 128 may be an oxide layer or a nitride layer, for example. Another photoresist layer 130 is then formed over the resulting structure, and patterned so as to expose the NFET device 104 as shown in FIG. 1( f ). Another directional RIE process is then used to remove both the hardmask layer 128 and horizontal portions of the spacer layer 120 , thereby forming thin sidewall spacers 132 on the NFET gate stack structure 112 b . In FIG. 1( g ), the photoresist layer 130 over the PFET device 102 is removed, and NFET raised source/drain structures 134 are epitaxially grown on the ETSOI layer 108 . The raised source/drain structures 134 are of a second semiconductor type that will serve to provide a tensile stress on the NFET channel. In an exemplary embodiment, the raised source/drain structures 134 comprise silicon carbon (Si:C).
Similar to the formation of the PFET SiGe RSD structures 126 described above, formation of the NFET RSD structures 134 is also performed by in-situ doping with a suitable n-type dopant material, such as phosphorus (P) for example. As is also the case with the SiGe RSD structures 126 , instead of a faceted RSD sidewall profile, the Si:C RSD structures 134 have vertically disposed sidewalls that abut the thin spacers 132 , which keeps silicide contact formation away from the channel region without the need for forming a second spacer. Again, the vertically profiled Si:C RSD structures 134 enhance the tensile stress provided to the channel, in comparison to a faceted sidewall profile.
In FIG. 1( h ), the device is subject to an anneal that drives in-situ n-type and p-type dopants from the RSD layers into the ETSOI layer, forming the source and drain extension regions 136 below the channel region of the transistors. The remaining hardmask layer over the PFET device 102 is also removed (either before or after the anneal). Finally, as shown in FIG. 1( i ), the gate nitride cap is removed, followed by a silicidation process as known in the art to form silicide contacts 138 , after which device processing may continue in accordance with existing techniques.
As will thus be appreciated, the present embodiments provide the capability of independently tuning raised source/drain regions in ETSOI substrates to optimize source/drain extension regions and stress conditions for NFET and PFET devices. In contrast to existing techniques, the techniques disclosed herein do not require a second spacer to prevent silicide encroaching into channel, as the vertical RSD sidewall profile keeps the refractory metal a consistent distance away from the channel, roughly corresponding to the height of the RSD structure. It should be appreciated, however, that a second spacer, if so desired, could be formed prior to refractory metal deposition in forming the silicide contacts.
While the invention has been described with reference to a preferred embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A method of forming a transistor device includes forming a patterned gate structure over a semiconductor substrate; forming a spacer layer over the semiconductor substrate and patterned gate structure; removing horizontally disposed portions of the spacer layer so as to form a vertical sidewall spacer adjacent the patterned gate structure; and forming a raised source/drain (RSD) structure over the semiconductor substrate and adjacent the vertical sidewall spacer, wherein the RSD structure has a substantially vertical sidewall profile so as to abut the vertical sidewall spacer and produce one of a compressive and a tensile strain on a channel region of the semiconductor substrate below the patterned gate structure.
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BACKGROUND OF THE INVENTION
This invention pertains to a system of shoring posts and supporting stands useful for storing boats out of water and particularly to a boat shoring system comprising individually adjustable and collapsible shoring posts and supporting stands securely interconnected with stabilizing cables to provide a boat cradle or support system readily adjustable to support variable size boat hulls removed from water.
Supporting systems or boat cradles for supporting boats in dry storage are known. For instance, U.S. Pat. No. 3,586,285 and U.S. Pat. No. 4,468,150 disclose boat blocks and boat cradles comprising fixed dimension wooden base members resting on the ground with adjustable vertical supports secured at the distal ends of fixed lateral members for supporting the hull section of a boat while U.S. Pat. No. 3,430,911 discloses laterally adjustable posts resting on a fixed lateral cross-beam. Similarly, U.S. Pat. No. 3,139,277 and U.S. Pat. No. 4,155,667 disclose adjustable support members for supporting a boat hull with a center keel. In said U.S. Pat. No. 4,155,167, sailboats are supported by vertical posts interconnected to a series of horizontal stabilizing pipes.
The prior art devices, however, are deficient in that the boat shoring structures are unstable, particularly with high center of gravity larger boats, and are not easily adjustable to accomodate various size boat hulls. Stabilizing heavy and bulky boat hulls against inadvertent shift requires equalizing and balancing supporting forces particularly important in maintaining safe storage of boats. Further, prior art showing structures are not easily dismantled for storage during non-use.
It now has been found that a plurality of individually adjustable shoring posts or stands can be independently adjusted both vertically and transversely to safely support a wide variety of boat hulls of different widths, lengths and heights. The individual shoring stands are securely stabilized with angularly directed lateral stabilizing cables or chains in conjunction with similar horizontally disposed stem to stern center cables or chains. The boat shoring system of this invention comprises two or more sub-systems where each sub-system includes a vertically adjustable central load bearing post adapted to support the keel of the vessel in combination with outer adjustable spaced shoring stands particularly directed inwardly on a vertical bias toward the central load bearing post to engage and support the boat. The interconnecting cables or chains prevent ground slippage of individual outer shoring stands in the system while the entire weight of the boat is supported evenly by the entire shoring system. The individually stabilized outer biased shoring stands provide inwardly directed biased supporting forces while being securely chained to prevent lateral ground movement thereof. The entire shoring system can be easily assembled and adjusted vertically and transversely for use or easily dismantled for compact storage of the individual parts thereof. These and other advantages of this invention will become more readily apparent by referring to the accompanying drawings as described in the appended specification.
SUMMARY OF THE INVENTION
Briefly, the boat shoring system of this invention comprises a plurality of interrelated supporting means adapted to be both vertically and transversely adjustable and securely anchored together by means of interconnecting cables or chains. The boat shoring system comprises at least two interconnected sub-systems where each sub-system contains a central load bearing post adapted to engage the central beam member of the boat hull in conjunction with at least two outwardly extending supporting stands disposed on either side of the central load bearing post and adapted to support the boat hull generally. The two outer supporting stands are particularly biased inwardly with inside legs thereof biased and shorter than outside biased legs thereof to off-set and stabilize the angular weight force imparted by the hull and supported by each outside supporting stand.
IN THE DRAWINGS
FIG. 1 is a plan view of the boat shoring system of this invention supporting a boat hull as shown in phantom lines;
FIG. 2 is a partial perspective view of the boat shoring system showing a forward sub-system assembly interconnected with rearwardly disposed partial sub-systems supporting a portion of a boat hull;
FIG. 3 is a front vertical view of a single sub-system assembly of the boat shoring system with the stern or bow of the boat shown in phantom lines;
FIG. 4 is a vertical perspective view of a central load bearing shoring post of the boat shoring system;
FIG. 5 is a side elevation view of the central load bearing shoring post shown in FIG. 4;
FIG. 6 is a top plan view of the central load bearing shoring post shown in FIG. 4 with member 17 rotated 90° and the upper load bearing block 12 removed and shown in phantom lines;
FIG. 7 is a vertical perspective view of a biased outside supporting stand of the boat shoring system;
FIG. 8 is a front elevation view of the biased outside supporting stand shown in FIG. 7; and
FIG. 9 is a top plan view of the biased outside supporting stand shown in FIG. 8 with the upper supporting block removed and shown in phantom lines.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings wherein like reference characters indicate like parts, FIG. 1 illustrates a boat shoring system of this invention shown in plan view the boat hull supported thereby being shown in phantom lines. As viewed in FIG. 1, the boat hull depicts the stern of the hull at the top of the drawing and the bow portion at the bottom of the drawing.
The boat shoring system of this invention comprises a plurality of individual vertically disposed shoring parts adapted to support the boat hull. The boat shoring system comprises two or more sub-systems wherein each sub-system preferably comprises a central load bearing shoring post 10 interconnected with a pair of outer biased supporting shoring stands 15 by lateral cables or chains 20. For supporting the boat hulls, the boat shoring system can include a plurality of load bearing shoring posts 10 as indicated supporting the keel portion of the boat hull in FIG. 1. Each standard sub-section includes lateral cables or chains 20 interconnecting the central load bearing posts 10 and said posts with adjacent outside biased supporting stands 15. The lateral cable means or chains 20 are literally adjustable and preferably interconnected between the lower base portion, preferably the base plate 14 of the posts 10 and the upper portion of each outside supporting stand 15 in such a manner as to maintain a taut angular interconnection, preferably in tension as best viewed in FIG. 3. As shown, hooks 21 on posts 15 are used to anchor chains 20 secured as by hooks 30 to the central load bearing shoring posts 10 to adjacent sub-systems. The posts 10 are interconnected by a taut center cable means or chain 25 between the lowermost base portion or base plate 14 of each such central load bearing post 10 while maintaining each center cable or chain 20 horizontally close to the ground as best viewed in FIG. 2.
FIGS. 4, 5 and 6 disclose in more detail a preferred embodiment of the central load bearing shoring post 10. The central shoring post 10 contains a horizontal base plate 14 preferably of heavy metal supporting a centrally located vertical tube 32 for receiving and supporting an adjustable threaded screw-lift load bearing member 34. The screw-lift member 34 contains outside threads adapted to be engaged by inside threaded member 36 adapted to be manually rotated 360° by adjusting crank means 17 to move the screw-lift member 34 upwardly or downwardly as desired. The uppermost end of the screw-lift member 34 is secured to a holding means 11 preferably having a wooden load bearing block 12 seated thereon for engaging the hull surface. The vertical tube 32 is supported by a plurality of bracing members 13 secured to the upper part of the vertical tube 32 and at their lower ends to the outer periphery of a flat horizontal base 14 for the post. The pair of cable or chain anchoring or hook means 30 disposed on the base 14 are adapted to receive an end of a chain 20 and said hooks are welded or otherwise secured to the base plate 14 and preferably further secured to an upper portion of the vertical tube 32 by similar means.
FIGS. 7, 8 and 9, further depict in further detail the preferred construction of the outside biased supporting stand 15. The outside supporting stand 15 contains four spaced leg members 23 maintained in a spaced relationship by an intermediate bracing plate 16 and an upper bracing plate 22. A center support tube 19 projects through an opening in the upper bracing plate 22 and said tube 19 is adapted to receive an exterior threaded support or screw-lift member 40 fitted within the short center support tube 19.
The threaded screw-lift support member 40 is operative to move upwardly or downwardly within the tube 19 by rotating an interior threaded collar 42 operative by rotating hand crank means 47 attached to the collar 42. As best shown in front elevational view in FIG. 8, the outer supporting stand 15 is disposed at an angle and/or biased inwardly with relatively longer angled outer legs and relatively shorter less angled or biased inner legs 23. The outside support stand 15 is angled or biased from a vertical line whereby threaded member 40 provides an angled support member having a large, flat, wooden supporting block 18 adapted to engage a center portion of the boat hull. The top plan view shown in FIG. 9 shows the supporting block 18 removed from the stand and in phantom lines further illustrates the degree of bias off-set from the vertical where the off-set is directed inwardly as viewed in FIGS. 8 and 3. A cable or chain anchor means or hook 21 is secured to the upper part of one of the shorter inner leg members 23 and is adapted to engage and secure a lateral cable or chain 20 tautly stretched between each outside stand 15 and a common central keel load bearing post 10 to comprise a sub-system assembly. Accordingly, two or more sub-systems are interconnected by a center chain 25 tautly interconnected between two or more central load bearing shoring posts 10. As best viewed in FIG. 3, lateral cable means or chains 20 are anchored to the bottom base member 14 of the common central post 10 and stretched upwardly and outwardly on an angle to securely engage anchor means 21 secured to the upper part of each outside supporting stand 15.
As shown in the preferred form of this invention illustrated in FIG. 1, the boat shoring system comprises two sub-system assemblies supporting the forward end of the boat hull with a plurality, preferably three, of load bearing posts 10 supporting the boat hull. The two forward and intermediate sub-systems each comprise a central keel load bearing post 10 in combination with two outside biased support stands 15 adapted to support either of the surfaces of the boat hull. The stern position load bearing posts 10 are adapted to support the relatively flat profile surface of the stern section boat hull. Where three load bearing posts 10 are utilized for the stern section, the center post engages the center beam or keel of the hull and is considered a central load post 10 whereas the central end posts 10 are considered support posts 10.
It is readily seen that the boat shoring system of this invention provides stabilized and balanced support to just about any size boat hull. The major weight force is a vertically downwardly directed force through the keel which is supported by the central load bearing post 10. Providing stabilized support to the forward portion of the boat hull requires biased supporting stands 15 and thus the upper supporting block 18 is tangentially orientated to the curved hull surface and essentially perpendicular to the load bearing threaded member 40 secured within the central support tube 19. As best viewed in FIG. 8, the inner leg members 23 are less angled or biased than the outer leg members 23 and the outer leg members 23 are at a greater angle to the vertical than the angle to the vertical of the load bearing threaded member 40 within the tube 19. The downward thrust of the boat weight is directed primarily on the outermost legs 23 although considerable weight is supported by the innermost legs 23 of each biased stand 15. To prevent lateral movement of the biased supporting stands 15 in use, lateral cables or chains 20 are tautly secured between upper anchor means 21 secured to the biased stands 15 and to the lower anchor means or hook 30 on the base plate 14 of the central load bearing post 10 whereby a structural triangle is formed between the ground, the central post 10, and each angled supporting stand 15. The downward vertical force on the central load bearing post 10 literally renders that point of the triangle immovable while the taut lateral chain renders the top or apex of the triangle immovable and the downward biased force on each biased support stand 15 renders the third ground point of the triangle immovable. Hence, the downward weight forces of the boat hull through each central post 10, in conjunction with both biased side stands 15, comprising a sub-system, advantageously promotes stability to the sub-system and particularly stabilizes the bias forces through the different skewed biases of the innermost legs 23 and outermost legs 23 with the central load bearing threaded member 40 at a bias less than the outside legs 23 but more than the bias of the inside legs 23. It should be further noted that the structural configuration of each biased outside stand 15 in itself forms a structural triangle comprising a load bearing point forming the upper point while the distal opposite ends are formed by ground resting points of the inner and outer legs 23. The third side of the triangle is formed by the ground between said respective ground or floor resting points of the inner and outer legs 23.
In use, the boat shoring system is easily assembled from a plurality of central posts 10 with complementary outside biased supporting stands 15 interconnected with lateral cables or chains 20 and center cables or chains 25, depending on the number of sub-systems utilized. Two or more central load bearing posts 10 are aligned with the keel or central beam member of the boat hull A center cable or chain 25 is stretched tautly between each pair of central posts 10 and secured therebetween by locking engagement with the respective anchor means 30 secured to the base plate 14 whereby the center cables or chains 25 are maintained substantially horizontal and close to ground level. Each central post 10 is a load bearing post and provides the center post for each sub-system assembly. The vertical height of each central post 10 can be adjusted by rotating the adjusting crank 17.
Each sub-system comprises a central load bearing post 10 interconnected with a pair of complementary side supporting posts 15 disposed laterally of and above on either side of the central post 10. Lateral side cables or chains 20 securely anchored to the base plate 14 of the central post 10 are stretched upwardly on an angle and tautly secured to anchor means 21 welded to the upper portion of each outer biased supporting stand 15. The boat hull dead weight is distributed primarily on the central load bearing posts 10 and partially distributed on each of the angled or biased outer supporting stands 15. The dead weight of the boat hull increases the tension on the lateral cables or chains 20 as well as the center cable or chains 25 which further increases the stability in use of the boat shoring system of this invention. The boat shoring system is easily assembled for use with various size boat hulls and can be easily disassembled and compactly stored, while not in use.
Although the foregoing drawings and description discloses preferred embodiments of the boat shoring system of this invention, the scope of the invention is not intended to be limited except by the appended claims.
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A boat shoring system for cradling and supporting a boat in dry storage comprising two or more interconnected sub-system assemblies. Each sub-system comprises a central load bearing post and two laterally spaced outside supporting stands securely interconnected with laterally adjustable and angularly directed cable or chain means tautly stretched and preferably in tension to stabilize lateral movement. Two adjacent sub-systems are further stabilized by tautly stretched center cable means. The load bearing posts and outside supporting stands are vertically adjustable and transversely movable both laterally as well as forwardly and rearwardly. The boat shoring system can be easily assembled for use or dismantled into individual components and compactly stored during non-use.
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RELATED APPLICATIONS
This application claims priority from U.S. provisional application No. 60/156,813 filed on Sep. 29, 1999, entitled “A Reconfigurable Web-Server and Modem in a Microcontroller” which is incorporated by reference herein in its entirety, and is related to U.S application Ser. No. 09/431,388, filed on Nov. 01, 1999, entitled “System and Method for Byte-at-a-Time Processing for Communication Protocols”, which is incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to the field of computers and more particularly to external file access procedures in resource limited computer systems.
2. Description of Background Art
The ubiquity of the Internet is driving the inclusion of Transmission Control Protocol/Internet Protocol (TCP/IP) stacks in smaller and cheaper devices. Meeting the price and space demands of embedded applications forces designers to look for an alternative to the 32-bit processors historically required for TCP/IP.
As more products are designed with networking capabilities there is a need for networking functionality to be available at a lower price point. The TCP/IP protocol was designed to operate on 32-bit workstations. Consequently, the protocol makes few concessions to resource limited devices like embedded 8-bit microcontrollers.
One of the difficulties of using a resource limited microcontroller to implement a TCP/IP stack is that when data frames are sent, a data validity check value, e.g., checksum or cyclic redundancy check (CRC), is necessary to ensure that the frame is not corrupted during transmission. Conventional TCP/IP stack implementations buffer the entire frame such that a data check function can be performed on the frame. However, these conventional systems require that memory be used to buffer the frame. This is not a feasible option in devices where the amount of on-chip random access memory (RAM) is already small and any use of the RAM could significantly affect the performance of the device.
Another alternative is to limit the size of the data packets in order to minimize the amount of data that needs to be buffered. However, limiting the size of the data packets would decrease the efficiency of the system. Using smaller packets requires that more packets are sent in order to communicate the same amount of data. Since a portion of each packet is usually set aside for addressing and protocol information, smaller packets result in a lower proportion of the bytes being sent being data bytes and thus a lower efficiency. If the link is used less efficiently, then a faster, more complex, and more expensive, physical interface might be required to send the data in the same amount of time
A third possibility is that the no redundancy check is performed and the data is sent without being buffered. However, such a reduction in reliability is unacceptable for many potential uses of resource limited devices.
What is needed is a TCP/IP communications protocol system and method that is compatible with legacy systems and that uses a resource limited computer, e.g., an 8-bit microprocessor or microcontroller, that (1) reduces or eliminates the need for buffering (2) does not require addition additional memory, (3) does not require limiting the size of data packets; and (4) is reliable.
Another use of resource limited devices (processors) is to locate files stored in external memory, e.g., electrically erasable and programmable read only memory (EEPROM). For example, in order to access a web page on a web server, the device needs to identify the uniform resource identifier (URI). This URI typically corresponds to a file path in a file system. For example, the file “logo.gif” in the sub-directory “images” could have the URI: “/images/logo.gif”. In conventional file systems, a table of file names is stored along with pointers that identify the memory address at which the file data begins. Finding a particular file is achieved by searching through the table of file names, e.g., URIs, until a match is found. There are a variety of ways for optimizing this search, such as structuring the search as a tree. The use of hashing functions is possible, but in conventional systems the file name, e.g., the URI, still needs to be stored in the device when using hashing functions.
In resource limited devices, storing the file names, e.g., URIs, of the relevant files is an inefficient and impractical use of the limited memory resources on the device.
What is needed is a data storage and lookup procedure for use on resource limited computers, e.g., 8-bit microcontrollers, that will enable files stored in external memory to be identified without requiring that the file names or paths, e.g., URIs, be stored on the internal computer memory.
SUMMARY OF THE INVENTION
The invention is a system and method that computes a hash function based upon the file name, e.g. a URI, that is to be identified in a look-up table stored in external memory. The hash value is multiplied by a first multiplier. The result is used as a pointer to a lookup table that is stored in external memory. The present invention avoids the need to perform string comparisons or to store any file names or addresses on the server.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of an environment in which the preferred embodiment of the present invention operates.
FIG. 2 is an illustration of the relation of the present invention to the application layer, transport layer, and Internet layer of a network.
FIG. 3 is an illustration of microcontroller in which the present invention operates.
FIG. 4 is flowchart of the packet transmission processes according to the preferred embodiment of the present invention.
FIG. 5 is a flowchart of the packet receiving process according to the preferred embodiment of the present invention.
FIG. 6 is flowchart of the hashing processes according to the preferred embodiment of the present invention.
FIG. 7 is an illustration of a format of the external memory file system that is used in the hash table lookup aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of the present invention is now described with reference to the figures where like reference numbers indicate identical or functionally similar elements. Also in the figures, the left most digit of each reference number corresponds to the figure in which the reference number is first used.
The present invention solves many of the challenges in squeezing a TCP/IP stack and a web server into a resource limited computer, e.g., a single, high-performance, low-cost, 8-bit microcontroller such as the 50MHz SX Microcontroller that is commercially available from Scenix Semiconductor, Inc., Santa Clara, Calif. In the preferred embodiment the stack is modular and, in different configurations, can fit into any device in the SX family. The code size of the web-server and modem is dictated by the choice of the SX48/52BD devices. These are 8-bit, modified Harvard architecture microcontrollers in a 48 or 52 pin package. They have 4k words of program memory and a 262 byte SRAM register file. The SX48/52BD can be clocked from 0 to 50 MHz and has single cycle instruction execution and deterministic interrupt response making it suitable for software implementations of hardware functions.
An issue encountered during the implementation of one embodiment of the present invention was allowing the stack to process packets larger than the total RAM size of the microcontroller. This was achieved by using the byte-at-a-time processing technique of the present invention coupled with state-machines for decoding packet structure. The protocol stack and modem are implemented in software and can be easily modified and even upgraded in the field using the in-circuit programming capability of the Scenix microcontroller. The byte-at-a-time processing technique provides significant benefits even when the packet size does not exceed the allocated RAM of the microcontroller.
FIG. 1 is an illustration of an environment in which the preferred embodiment of the present invention operates. The environment includes a server 102 and a client 104 that are connected via a network, e.g., the Internet. The server 102 and/or the client 104 may be a SX series microcontroller that is commercially available from Scenix Semiconductor, Inc., Santa Clara, Calif. When information is requested by the client 104 , an information request command is transmitted to the Server 102 via the network 106 . The operation of the network is well known to persons skilled in the art. Both the client 104 and the server 102 have a TCP/IP stack having, for example, a network access layer, an Internet layer, a transport layer and an application layer. Additional layers can be included without departing from the scope of the present invention. A more detailed illustration of the layers is set forth in FIG. 2 .
In the preferred embodiment, the standard Point-to-Point Protocol (PPP) is used to manage the serial link between the resource limited device and any serial receiving device, e.g., a modem. This enables the stack to connect to any other machine running PPP such as an Internet Service Provider (ISP). The stack has both User Datagram Protocol (UDP) and Transmission Control Protocol (TCP) transport mechanisms for use in different applications. The Hypertext Transfer Protocol (HTTP) is used at the application layer to provide a web-server. In the preferred embodiment, the web-server resources, e.g., HTML, images or applets, are stored in a file system in an external EEPROM. Only the EEPROM size and the bandwidth of the physical link limit the size of these resources.
FIG. 2 is an illustration of the relation of the present invention to the application layer, transport layer, and Internet layer of a network. In the preferred embodiment, the Internet layer includes the Internet Protocol (IP) 202 , the transport layer includes both the UDP 205 and TCP 204 transport protocols. Other transport layer protocols can be used in addition to or in place of these protocols. In the preferred embodiment the application protocol 206 communicates with the TCP 204 using the byte-at-a-time processing technique of the present invention. In alternate embodiments, the present invention could be used between other protocols in the TCP/IP stack or other protocol stacks, e.g., the infrared data association (IrDA) protocol stack.
FIG. 3 is an illustration of microcontroller in which the present invention operates. FIG. 3 illustrates an SX microcontroller which in some embodiments of the present invention may be used as the client 104 and/or the server 102 . It is envisioned that the present invention can be used with a variety of computers and is not limited to the SX series as described with reference to the preferred embodiment. The SX microcontroller 301 includes a flash program memory 302 , a static random access memory (SRAM), an arithmetic logic unit (ALU) 306 , input/output ports 308 and interfaces, e.g., an I 2 C Interface 310 , which may communicate with external memory, e.g. an EEPROM 320 . The flash memory includes the network stack, an application and a physical interface. In the preferred embodiment, the byte-at-a-time processing is performed using operations stored as an application in the flash program memory 302 . The operation of the byte-at-a-time processing application is described below with respect to FIGS. 4 and 5. In the preferred embodiment, the off-chip EEPROM 320 is where the hash-file system is stored. A more detailed description of the operation of the hash file storage system is described below with reference to FIG. 6 .
FIG. 4 is flowchart of the packet transmission processes according to the preferred embodiment of the present invention. As described above, on-chip RAM, e.g., SRAM 304 , is expensive and adding an external RAM chip would increase the component count, along with increasing the size and cost of the device. Since the TCP/IP stack is only a tool to be used by the application running on the same microcontroller, it should use as little RAM as possible. One method of reducing the memory footprint of the network stack is to have a policy of not buffering any information at all. This requires that the packet be transmitted byte-by-byte as it is generated, and that a received packet be processed byte-by-byte as it is received.
If the network stack can meet this constraint, then it is up to the application to determine how to manage its own memory. The application can also adopt a byte-by-byte approach to conserve RAM. For the application this means that any transmitted information must be reproducible. If a remote host requests retransmission of a packet then the application must generate the data again since there will be no buffered copy to retransmit.
If the application cannot reproduce the data then it can buffer the data portion of each packet. There is still a savings here of at least 28 bytes per packet because only the data is being buffered. The 28 bytes represent the size of the non-data portion of each frame. In the preferred embodiment of the present invention, none of the data is buffered. In alternate embodiments, some data may be buffered, but the amount of data that is buffered is less than the data in a frame. For example, in an alternate embodiment, data is sent two-bytes-at-a time as opposed to one-byte-at-a time as in the preferred embodiment. In other embodiments, eight bytes or more may be sent at a time. In these alternate embodiments, buffering of the data is required, although the entire data frame need not be buffered.
As described above, most protocols require validity checks of the data to ensure proper transmission and receipt. For example, the TCP/IP stack requires checksums and CRCs for data integrity at multiple levels in the stack. Some of these pose a problem for the byte-by-byte processing strategy of the preferred embodiment.
For example, PPP uses a 16-bit CRC which is computed over the entire packet and transmitted in the trailer. Since it is sent in the trailer there is no problem with computing the CRC as each byte is sent.
The Internet Protocol (IP) has a 16-bit checksum over the header which is transmitted in the header. Since it is computed from variables which are stored in RAM anyway there is no problem.
The UDP uses a 16-bit checksum over the UDP header and data which is transmitted in the UDP header. Fortunately the UDP specification (RFC768) allows for the checksum to be zero, in which case it is not checked by the recipient. However, ignoring the UDP checksum does not make the stack more susceptible to errors since all packets are protected by the PPP CRC.
The TCP has a 16-bit checksum, computed over the TCP header, a pseudo header and TCP data and transmitted in the TCP header. This is not optional and poses a problem for the byte-by-byte stack since earlier bytes depend upon bytes which haven't been processed yet.
Three potential solutions to this problem are: (1) transmit a dummy checksum in the TCP header and pad the TCP data with bytes to make the dummy checksum correct; (2) buffer the TCP data so the checksum can be computed; or (3) have the application produce the same stream of bytes twice, once to compute the checksum and the second time to transmit the data.
The first solution appears attractive, but when used with existing protocols like HTTP or SMTP there is no way to tell the application protocol when to ignore the extra bytes at the end of the payload.
The second solution is contrary to the byte-by-byte philosophy, and requires significant buffering of data.
The third solution is the solution implemented as part of the preferred embodiment of the present invention. The application still has the option to buffer the data itself, or, such as the case with HTTP, it can just transmit the same data twice.
In the preferred embodiment, an application program interface (API) can be used by applications that want to use TCP. The API is event driven, i.e., when the stack is able to send a packet it queries the application to see if there is any data to send. If the application is listening on a port, the TCP will inform the application as each byte is received. One example of such an API is set forth below in Table 1.
TABLE 1
AppInit
Called to allow the application
to initialize variables and do
a passive open if the
application is a server.
AppBytesToSend
Called by the TCP to see if the
application has any data to
transmit. The application
should return with the number
of bytes it wishes to send in
the {grave over ( )}w′ register.
AppBytesAvailable
Called by the TCP when a packet
is being received. {grave over ( )}w′ contains
the number of bytes of data
that will be received. This
routine is a warning to the
application that its AppRxData
routine is about to be called
{grave over ( )}w′ times.
AppTxData
Called once for each byte to be
sent in a packet. The byte to
be transmitted should be
returned in {grave over ( )}w′
AppRxData
Called once for each received
byte. Until the complete packet
has been received, the TCP
cannot be sure whether the
packet has been corrupted in
transmit. Therefore the
application should not make any
irreversible changes based on
the incoming data, until
AppPacketOK is called.
AppAck
Indication to the application
that the last packet
transmitted has been
acknowledged. This indicates
that the packet will not need
to be transmitted again.
AppNak
Indication to the application
that the last packet has not
been acknowledged. Subsequent
calls to AppTxData should
return the same packet data
again because the packet will
be transmitted again.
AppPacketOK
The last packet received was
not corrupt. At this point the
application can use the packet
data.
AppPacketBad
The last packet received was
corrupt. The application should
expect to receive the packet
again.
Given the above description, an implementation of each API will be apparent to people skilled in the art.
With reference to FIG. 4, when the application prepares to transmit a byte of data, it determines 404 whether a validity check is necessary (this step could also be done after generating each byte of data). If no validity check value is necessary the byte can be generated and transmitted 414 . If a validity check is to be performed, the application continually generates 406 a byte of data until all data in a packet is generated 408 (the number of bytes to be sent can be identified by using “AppBytesToSend” or the like). The application then generates 410 the validity check value, e.g., a checksum or CRC.
As described above, in the preferred embodiment of the present invention the packet data is not buffered, so in order to transmit the packet, the application will regenerate the byte. Each byte in the packet is generated and transmitted 414 sequentially (AppTxData). When all of the bytes of the packet have been transmitted 416 the transmitting device awaits an acknowledgment from the receiving device that indicates that the packet has been properly received. If the packet has been received 418 , the application transmits 424 an application acknowledge signal “AppAck” indicating that this data will no longer need to be reproducible. The device can limit the amount of time it will wait for a packet receive acknowledgment by using a timer. When the timer expires 420 a not acknowledged signal “AppNak” is returned and the application begins again with step 404 .
FIG. 5 is a flowchart of the packet receiving process according to the preferred embodiment of the present invention. When receiving a packet, the application identifies the number of bytes in the received packet (AppBytesAvailable). One technique for accomplishing this is used by the TCP/IP protocols which transmit the size of each packet in the packet header. An application in the client device 104 then receives 504 each byte (AppRxData) until all bytes in the packet are received 506 . The client application then determines 508 whether the validity check value (VCV), e.g. a CRC, is correct. If the VCV is not correct the application identifies the packet as corrupt 510 (ApppacketBad) and a signal is optionally sent to the server 102 requesting that the packet be resent. The client application then awaits for the packet to be received again. If the VCV is correct 508 then the client application identifies 512 the packet as not corrupt and a packet acknowledgment is transmitted to the server which is received as described in step 418 if the server 102 is using the byte-at-a-time feature. It will be apparent that both the client 104 and server 104 do not need to be using the present invention. Instead, the present invention will operate successful even if only one of the client 104 and server 102 utilize the invention.
It will be apparent to those skilled in the art that modifications can be made to the above described preferred embodiments without departing from the scope of the present invention of transmitting information a unit at a time, where the unit can be a byte, multiple bytes, or a buffer, for example.
As described above, resources on a web-server are specified by a name in string form, known as a Uniform Resource Identifier (URI). Typical strings might be “/index.html”, “/images/scenix. gif”, or “/applets/com/scenix/demo/Bounce.class”. A web-server should not make assumptions about the maximum length of a URI, since the maximum length is not defined and if it were, many URIs would not approach such a maximum. This poses a problem for memory limited devices since in order to accommodate URIs a large amount of memory would need to be reserved (and even then, the amount of memory to reserve is unknown since the maximum URI length is unknown). The present invention solves this problem by using a modified a hash table lookup at the server with an external memory storing the actual URIs.
FIG. 6 is flowchart of the hashing processes according to the preferred embodiment of the present invention and FIG. 7 is an illustration of a format of an external memory file system that is used in the hash table lookup aspect of the preferred embodiment of the present invention.
A hash function (for example., an unsigned 8-bit sum of the ASCII values of the characters in the URI) is computed over the URI of a “GET” request. The hash value is then multiplied by two and used as a lookup into a 512 byte table of 16-bit file offsets (called the index block 702 ). In one embodiment, hashing collisions are ignored. Some benefits of the present invention is that no string comparisons need to be performed (which are expensive and time consuming to perform) and no URIs need to stored on the server 102 .
When the lookup table is created the user is capable of changing the URIs of any resources which have a hash collision, in some embodiments of the present invention. It is possible that a GET request might contain a URI which does not exist on the web-server but which hashes to the same value as a resource which does exist. In this situation the incorrect resource will be returned. However, since most GET requests are generated as the result of hyperlinks from other resources it is unlikely that an erroneous URI will be generated.
The web-server resources are stored in an external serial EEPROM 320 . In the preferred embodiment this EEPROM 320 is 32 k bytes in size, but it could be up to 64 k bytes without any code changes.
The operation of the process is now described with reference to FIG. 6. A file path and name are received 602 by the application in the server 102 . The application determines the hash value of the file path and name. Many different hash functions can be used. In the preferred embodiment, the hash function is an unsigned 8-bit sum of the ASCII numeric values of the characters in the URI. For example, if the file path and name is “/index.html” then the hash value is: (47+105+110+100+101+120+46+104+116+109+108)(Mod 256 )=42. Similarly, the hash value of “/images/scenix.gif” is 74 . These hash values are used as indicies into the index block 702 . Then entry into the index block is the offset to the start of the actual file, as illustrated in FIG. 7 .
After determining 604 the hash value for the file path and name the application in the server 102 uses 606 the hash value as an index into an index block in the external memory 320 . The offset is read 608 from the index block. The server 102 then retrieves 610 the file at the offset address in the external memory 320 .
In alternate embodiments, a verification system can be used to ensure that the file chosen using the hashing function is the correct file. For example, the beginning of each file could have another hash value corresponding to another hash function, e.g. a 16-bit hash. This will reduce the possibility of using an incorrect file due to collisions, for example. If a collision does occur then a collision resolution technique could be used, e.g. double hashing. A description of various collision resolution techniques is set forth in Knuth, The Art of Computer Programming, Vol. 3, (Addison-Wesley, 1998), which is incorporated by reference herein in its entirety. As described above, the external memory 320 can be any type of memory device and is not limited to EEPROM.
The following references pertain to various issues of the present invention and are all incorporated by reference herein in their entirety: (1) (RFC1661) W. Simpson (Ed), “The Point-to-Point Protocol”, IETF Request for Comments, July 1994; (2) (RFC1662) W. Simpson (Ed), “PPP in HDLC-like Framing”, IETF Request for Comments, July 1994; (3) (RFC1332) G. McGregor, “The PPP Internet Protocol Control Protocol (IPCP)”, IETF Request for Comments, May 1992; (4) (RFC791) “Internet Protocol”, IETF Request for Comments, September 1981; (5) (RFC792) “Internet Control Message Protocol”, IETF Request for Comments, September 1981; (6) (RFC768) J. Postel, “User Datagram Protocol”, IETF Request for Comments, August 1980; (7) (RFC793) J. Postel (Ed), “Transmission Control Protocol”, IETF Request for Comments, September 1981; and (8) (RFC2068) R. Fielding et. al. “Hypertext Transfer Protocol—HTTP/1.1″, IETF Request for Comments, January 1997.
While the invention has been particularly shown and described with reference to a preferred embodiment and several alternate embodiments, it will be understood by persons skilled in the relevant art that various changes in form and details can be made therein without departing from the spirit and scope of the invention.
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A system and method that computes a hash function based upon the file name, e.g. a URI, that is to be identified in a look-up table stored in external memory. The hash value is multiplied by a first multiplier. The result is used as a pointer to a lookup table that is stored in external memory. The present invention avoids the need to perform string comparisons or to store any file names or addresses on the server.
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BACKGROUND OF THE INVENTION
This invention is directed generally to metal halide table and floor lamps and their manufacture. More particularly, this invention is directed to metal halide table and floors lamps which advantageously separate an easily replaceable, metal halide bulb from its associated power supply, ballast, and control circuits while presenting a conventional lamp appearance. The invention is further directed to a method of manufacture of such lamps which provides for assembly by those of but ordinary skill.
The advantages of metal halide lighting include excellent lighting characteristics, exceptional long bulb life, and low cost per lumen of light output. These advantages are well known and have been exploited in various outdoor and industrial indoor applications, e.g., exterior street lighting, racket ball and other interior sports area lighting, and interior warehouse area lighting.
Previously, metal halide lighting for conventional interior portable residential table and floor lamps, has not been practical due to limitations associated with metal halide bulbs, e.g., size, volume, and power requirements of bulb power supply and ballasts as well as safety concerns with metal halide bulb explosions.
Prior art efforts to overcome these problems have not been completely successful. For example, previous metal halide bulbs for use in interior lamps have suffered being unsightly, expensive, being less efficient, from slow startup times and hot restart problems. General Electric has produced the Halarc (tm) and Miser (tm) Maxi-Light (tm) which feature conventional edison base bulbs for use with existing socketed lamps. However, these bulbs include, as part of the lower portion of the bulb base, an unsightly electronic control capsule which includes the power supply, ballast and controls required by the metal halide bulb. The control capsule give the bulb an unsightly bulging appearance which is unacceptable when viewed within a lamp. Additionally, the control capsule increases the cost of the bulb and provides a lumen efficient of less than three, i.e., 150 watts of "incandescent" light for 55 watts of power.
An important advance in the art is made and many of the problems of the prior art are obviated by the current invention.
Accordingly, it is an object of the present invention to provide a novel metal halide lamp and method of manufacture suitable for use as a table or floor lamp.
It is another object of the present invention to provide a novel modularized metal halide table or floor lamp and method of manufacture enabling those of but ordinary skill to assemble the final lamp.
It is yet another object of the present invention to provide a novel lamp including a base housing electronic components separate from a metal halide bulb permitting maintenance of the electronic components and easy, economical replacement of the metal halide bulb.
It is a further object of the present invention to provide a novel lamp advantageously utilizing both metal halide and incandescent bulbs which may be operated individually or in combination.
It is yet a further object of the present invention to provide a novel metal halide lamp modular manufacturing method permitting final lamp assembly by those of but ordinary skill.
It is still another object of the present invention to provide a novel lamp including a base housing electronic components and a separate metal halide bulb positioned proximate an aperture for transferring light from the base to a light transport means.
It is still a further object of the present invention to provide a novel metal halide lamp having a liquid crystal light control aperture.
These and many other objects and advantages of the present invention will be readily apparent to one skilled in the art to which the invention pertains from a perusal of the claims, the appended drawings, and the following detailed description of the preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial representation of one embodiment of the present invention.
FIG. 2 is an illustration of couplings including integrated wiring contacts.
FIG. 3 is a pictorial representation of another embodiment of the present invention.
FIG. 4 is a pictorial representation of another embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to FIG. 1, the present invention is illustrated by a preferred embodiment suitable as either a floor or table lamp. Lamp 10, illustrated in FIG. 1, includes three interconnecting modules: base 20, luminaire 30 enclosing metal halide bulb 40, and joining member 50. Base 20 includes an internal cavity which provides a mounting area for the electronic components required by the metal halide bulb 40. Advantageously, the invention overcomes problems of the prior art by permitting maintenance of the electronic components and facilitating use of an attractive, economical, and easy to replace metal halide bulb.
Lamp 10 may further optionally include couplings 60 and quick-connect wiring connectors (not shown) which permit easy lamp assembly by those of but ordinary skill by coupling luminaire 30 and base 20 to joining member 50. The quick-connect wiring connectors are conventional and may, for example, include: snap together connectors; twist together connectors; coded twist together wiring with separate protective caps; and plug and socket complimentary connectors. Joining member 50 may be of any desirable length, e.g., of several feet for a floor lamp or of several inches for a table lamp. Alternatively, the joining member may be omitted by including mating couplings 60 on base 20 and luminaire 30. Manufacturing base 20, luminaire 30, and joining member 50 with complimentary sized couplings 60, permits manufacturing each modules in a wide variety of sizes and appearances while retaining easy assembly. The invention's method of manufacturing and assembly thus overcomes prior art problems of manufacturing metal halide lamps meeting the aesthetic and functional requirements of various manufacturers while permitting assembly by those of but ordinary skill.
In an optional embodiment, FIG. 2, the couplings 60 may integrated wiring contacts 75 obviating the requirement for quick-connect wiring connectors. The couplings 60 are conventional and may, for example, be: twist and lock; screw together; snap together and slip together.
FIG. 3 illustrates another preferred embodiment of the present invention also suitable as either a modularized floor or table metal halide lamp. Lamp 10 of FIG. 3 includes three interconnecting modules: base 20, luminaire 30 enclosing metal halide bulb 40, and joining member 50.
Base 20 includes base coupling 60. Luminaire 30 includes luminaire coupling 100. Joining member 50 terminates with lower coupling 70, mated to base coupling 60, and upper coupling 80, mated to luminaire coupling 100. Joining member 50 further includes an internal passage containing a high-voltage wiring harness 90. In the embodiment illustrated by FIG. 3, wiring harness 90 terminates as part of lower coupling 70 and upper coupling 80 such that lower coupling 70 and upper coupling 80 serve the dual functions of electrical connections and mechanical connections between base 20, joining member 50, and luminaire 30. Optionally, the various couplings may be provided with internal openings and wiring harness 90 may utilize conventional terminations. This optional arrangement thereby allowing wiring harness 90 to pass through lower coupling 70 and base coupling 60 to connect with associated wiring in base 20. Similarly, wiring harness 90 can pass through upper coupling 80 and luminaire coupling 100 to connect with associated wiring in luminaire 30.
As shown in FIG. 3, base 20 incorporates a cavity within which power supply 110, ballast 120, and illumination controls 130 are mounted and via wiring 140 connected to base coupling 60. Lamp switch 160 is mounted on the exterior of base 20 and electrically connected to illumination controls 130. An access plate (25) provides an opening into the cavity of base 20 in order to perform maintenance on the components within the cavity. Optionally, power supply 110, ballast 120, and illumination controls 130 may be constructed as a single box assembly 150 having base coupling 60 incorporated therein. Further, the access plate may optionally include a safety interface to assure that there is no live voltage within the base after the access plate is removed.
These features of the present invention overcome prior art problems of power supply and ballast size, volume, and safety problems.
Power supply 110 receives power from household 110 volt AC power receptacle. Alternatively, power supply 110 could receive power from a 220 volt AC power receptacle. Ballast 120 is of a pulse-start, solid-state type thereby more rapidly starting the metal halide bulb, improving full-illumination startup time and improving lumen efficiency to four to five, e.q., 300 watts of "incandescent" light for 70 watts. The prior art metal halide bulbs took approximately 60 seconds to come to a full illumination level. This invention advantageously reduces that startup time to 40 seconds and preferably 30 seconds. In some preferred embodiments the startup time is reduced to 20 seconds.
Wiring harness 90 is desirably pulse rated for 600 volts.
Luminaire 30 further includes incandescent bulb 170. Illumination controls 130 allows the operation of metal halide bulb 40 and incandescent bulb 170 individually or in combination. Incandescent bulb 170 is also controlled by dimmer 180. Optionally, incandescent bulb 170 may be included as part of the ballast circuit to further enhance startup illumination during hot startup conditions.
To diffuse the light exiting the bottom of luminaire 30, diffuser 220 is installed. With further reference to FIG. 3, the luminaire 30 incorporates liquid crystal areas 190 under control of illumination controls 130. By varying the opacity of liquid crystal areas 190, the light exiting luminaire 30 is controlled. The present invention also envisions alternative means of controlling the opacity of liquid crystal areas 190 such as with dimmer switches or touch-pads.
The luminaire 30 FIG. 3 consists of upper section 200 and lower section 210 serving as the lamp shade or globe. In this embodiment these of rigid glass construction offering protection from the possible explosion of metal halide bulb 40. In other alternative embodiments, luminaire 30 may consist of mixed glass and fabric sections or all fabric sections. Additionally, luminaire 30 may utilize a single piece shade or globe.
In some embodiments of the invention desirably utilize protective metal halide bulb shield 230 which may further optionally include air ports 240. Shield 230 is manufactured of glass suitable to withstand the heat given off by metal halide bulb 40.
FIG. 4 is a pictorial representation of another preferred embodiment of the present invention. The lamp of this embodiment consists of three modules: base 10, light transport 55, and luminaire 30.
Base 10 serves as an enclosure for both metal halide bulb 40 and electronics 50 for powering and operating bulb 40. Base 10 further includes an aperture 65 permitting the light from bulb 40 to exit the base 10. As shown in FIG. 4, bulb 40 is positioned proximate aperture 65. Optionally, lens 78, positioned intermediate bulb 40 and aperture 65 enhances the light transmission from bulb 40 through aperture 65.
Air ports 115 provide a means of dissipating heat from base 10. Placing air ports 115 within an area enclosed by light transport 20 assures efficient heat convection away from the base without concern of air ports 115 becoming clogged from dust or other particles coming in contact with the remaining external surfaces of base 10. In alternative embodiments of the present invention, the base 10 may not be fully enclosed, thereby obviating the need for air ports 115.
To provide for easy replacement of electronics 50 and metal halide bulb 40, base 10 includes as access plate (25). While in the embodiment of the present invention illustrated by FIG. 4, the lamp electronics 125 comprise a single assembly box, other optional embodiments of the invention mount a power supply, ballast, and illumination controls within base 10. In still other embodiments, the power supply and ballast are outside base 10, e.g., integral with the lamp power cord or integral with the power plug. In these embodiments, the illumination controls may also be outside base 10, e.g., integral with the lamp power cord or within a remote wireless control.
Light transport 20 connects base 10 at aperture 60 to luminaire 30 at aperture 85. Light transport 55 functions to transport light from aperture 60 to aperture 85. In the preferred embodiment illustrated by FIG. 4, light transport 55 includes an internal passage containing light pipe 95 which meets aperture 60 and aperture 85 to achieve the light transport function. The light pipe is conventional, for example, may be of glass, plastic, and plastic film. In alternative embodiments of the invention light pipe 95 is not used and light transport 55 transports the light from base 10 to luminaire 30.
Luminaire 30, as shown in FIG. 4, having received the light from transport 20, disperses light through lens 110 and frosted diffuser 100. In other optional embodiments of the present invention, lens 118 and lens 78 may be replaced by, or supplemented with, liquid crystal gates. Varying the opacity of the liquid crystal gates controls the transfer of light exiting base 10 and entering luminaire 30 respectively. Still other embodiments provide selectably controllable liquid crystal areas on the exterior surface of luminaire 30 for the purpose of controlling the light exiting luminaire 30. While the lamp illustrated by FIG. 4 diffuses light through diffuser 100, an alternative embodiment includes a light reflector with luminaire 30. Optionally, liquid crystal regions with selectable degrees of reflectance may be mounted on the light reflector in order to selectively control the amount of light reflected off the reflector and thereafter exiting luminaire 30.
Further optional embodiments of the present invention as illustrated in FIG. 4 may provide a bulb socket and wiring for an incandescent bulb within luminaire 30.
While not essential, an alternative embodiment of the invention similar to that illustrated by FIG. 4 also includes couplings 120. Couplings 120 facilitate modular construction of base 10, light transport 55, and luminaire 30 with their later assembly into a lamp by those of but ordinary skill.
While preferred embodiments of the present invention have been described, it is to be understood that the embodiments described are illustrative only and the scope of the invention is to be defined solely by the appended claims when accorded a full range of equivalence, many variations and modifications naturally occurring to those of skill in the art from a perusal hereof.
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Metal halide table and floor lamps and method of manufacture. A lamp base module housing a power supply, ballast, and illumination controls separate from a metal halide bulb with the metal halide bulb housed within the base or a luminaire module. Lamp modules of various size and appearance may be manufactured separately and easily assembled by those of but ordinary skill.
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BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a modular desk, and more particularly to a ready-to-assemble modular desk.
2. Description of the Related Art
Ready-to-assemble (RTA) furniture has many advantages including, being cheap to manufacture, easy to assemble and saves space during transportation and storage.
However, a person can only assemble RTA furniture as designed so an RTA desk has a set orientation and the person cannot customize the number and orientation of drawers, shelves and desktops. Moreover, the RTA desk requires tools for assembly and disassembly that dissuades some people from buying the RTA desk.
The present invention provides a ready-to-assemble modular desk to obviate or mitigate the shortcomings of the conventional RTA desk.
SUMMARY OF THE INVENTION
The primary objective of the present invention is to provide a ready-to-assemble (RTA) modular desk that is easily assembled and disassembled, and allows a person to customize the RTA modular desk.
The RTA modular desk in accordance with the present invention has multiple clasp connectors, two desk assemblies, a door and at least one pedestal drawer. Each desk assembly has a pedestal, and a desktop having a bottom surface. The pedestal and a stand are constructed and mounted detachably on the bottom surface of the desktop using the clasp connectors.
The desk assemblies are connected detachably to each other using multiple latch assemblies. The door is mounted detachably on one of the pedestals. The pedestal drawers are mounted detachably in one of the pedestals. Therefore, the RTA modular desk can be assembled without using tools in a variety of orientations, allowing a person to customize the RTA modular desk to their needs and easily change or disassemble the RTA modular desk without using tools.
Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a first embodiment of a ready-to-assemble (RTA) modular desk in accordance of the present invention;
FIG. 2 is an exploded perspective view of a desk assembly of the RTA desk in FIG. 1 ;
FIG. 3A is an enlarged view of the desk assembly of the RTA desk in FIG. 1 ;
FIG. 3B is an enlarged view of a hinge of the a door in FIG. 3A ;
FIG. 4 is a partially exploded perspective view of a desktop and a drawer assembly of the RTA desk in FIG. 1 ; and
FIG. 5A is a partially exploded view of the desk assembly and the drawer assembly of the RTA desk in FIG. 1 ;
FIG. 5B is an enlarged assembling view of a drawer and a drawer rail in FIG. 5A ;
FIG. 6 is an exploded perspective view of a pedestal of a desk assembly of the RTA desk in FIG. 1 ;
FIG. 7A is a partially exploded perspective view of the desk assemblies in FIG. 1 , showing a latch assembly;
FIG. 7B is an enlarged view of a latch and a catch in FIG. 7A ;
FIG. 8 is an enlarged perspective view in partial section of a clasp assembly used to construct the RTA modular desk assembly in FIG. 1 ;
FIG. 9 is operational top views in partial section of the clasp assembly in FIG. 8 ;
FIG. 10 is a perspective view of a second embodiment of the RTA modular desk in accordance of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIGS. 1 , 2 and 6 , a ready-to-assemble modular desk in accordance with the present invention comprises multiple clasp connectors, two desk assemblies ( 10 ), an optional drawer assembly ( 18 ), a door ( 126 ), an optional shelf ( 127 ) and at least one pedestal drawer ( 225 ).
With reference to FIGS. 8 , and 9 , each clasp connector comprises a clasp bar ( 1225 ) and a clasp recess ( 1227 ).
Each clasp recess ( 1227 ) has an inner chamber and a shoulder ( 12271 ). The shoulder ( 12271 ) is formed on and protrudes from the inner chamber of the clasp recess ( 1227 ) and corresponds to the head ( 12254 ) on the rotating pin ( 12252 ).
Each clasp recess ( 1227 ) has an inner chamber and a shoulder ( 12271 ). The shoulder ( 12271 ) is formed on and protrudes from the inner chamber of the clasp recess ( 1227 ).
Each clasp bar ( 1225 ) comprises a base ( 12251 ) and a rotating pin ( 12252 ). The rotating pin ( 12252 ) has a neck, a lever ( 12253 ) and a head ( 12254 ). The neck of the rotating pin ( 12252 ) protrudes from the base ( 12251 ). The lever ( 12253 ) is mounted on the rotating pin ( 12252 ) to rotate the rotating pin ( 12252 ). The head ( 12254 ) is formed on and protrudes from the neck of the rotating pin ( 12252 ) and corresponds to the inner chamber of the clasp recess ( 1227 ). The head ( 12254 ) on the rotating pin ( 12252 ) of the clasp bars ( 1225 ) is inserted into the corresponding clasp recess ( 1227 ) and extends through the shoulder ( 12271 ) of the clasp recess ( 1227 ), the rotating pin ( 12252 ) is rotated so the head ( 12254 ) abuts the shoulder of the clasp recess ( 1227 ) to lock the clasp connector securely.
Each desk assembly ( 10 ) has a pedestal ( 12 ), an optional stand ( 14 ), an optional rear cover ( 15 ), and a desktop ( 16 ).
With further reference to FIGS. 2 , 3 A, 3 B, and 6 , the pedestal ( 12 ) comprises a pedestal base ( 121 ), two pedestal side panels ( 122 ), a pedestal rear panel ( 124 ) and a pedestal brace ( 125 ).
The pedestal base ( 121 ) is rectangular and has a rear edge and two side edges.
The pedestal side panels ( 122 ) have an inner surface, a bottom edge, a top edge and a rear edge. The bottom edges of the pedestal side panels ( 122 ) are mounted removably on to the side edges of the pedestal base ( 121 ) using the at least one clasp connector and the at least one dowel ( 1221 ).
Each inner surface of the pedestal panels ( 122 ) has multiple hole pairs formed in the inner surface corresponding to each other.
The pedestal rear panel ( 124 ) corresponds to and is mounted removably on the pedestal base ( 121 ) and the pedestal side panels ( 122 ) using the clasp connectors and the at least one dowel ( 1221 ).
The pedestal top brace ( 125 ) is connected between the pedestal side panels ( 122 ) using the clasp connectors.
The stand ( 14 ) comprises at least one leg, may be rectangular and is placed parallelly to the pedestal side panels ( 122 ) and has an inner surface, a top edge, a front edge and a rear edge.
The rear cover ( 15 ) is a rectangular board and has a top edge and two side edges. The two side edges are shorter then the leg of the stand ( 14 ) and are detachably mounted to the rear edge of the pedestal side panel ( 123 ) and the stand ( 14 ) using the multiple clasp connectors and the at least one dowel ( 1221 ).
The desktop ( 16 ) is rectangular, has a bottom surface, two side edges, a rear edge and a front edge. The edges of the desktop ( 16 ) are mounted removably on the top edge of pedestal side panel ( 122 ), the top edge of the stand ( 14 ) and the top edge of the rear cover ( 15 ) using the multiple clasp connectors and the at least one dowel ( 1221 ).
With further reference to FIGS. 7A and 7B , the side edge of the desktop ( 16 ) of one desk assembly ( 10 ) is detachably connected to the other along the front edge of the desktop ( 16 ) near the stand ( 14 ) using multiple latch assemblies and at least one dowel ( 1221 ).
Each latch assembly has a latch ( 262 ) and a catch ( 264 ) mounted respectively on the bottom surface of one of the desktops ( 16 ). The latch ( 262 ) has a latch mount ( 262 ) and a latch bar ( 2624 ). Each latch bar ( 264 ) is mounted rotatably in one of the latch mounts ( 2622 ) and has a latching end. Each catch ( 264 ) has a recess ( 2642 ) corresponding to the latching end of the latch bar ( 264 ). With further reference to FIGS. 4 , 5 A and 5 B, each pedestal drawer ( 225 ) has two sides and two rails ( 2222 ). The rails ( 2222 ) are mounted respectively on the sides of the pedestal drawer ( 225 ) and in the hole pairs of the inner surface of the pedestal side panels ( 122 ) and allow the pedestal drawer ( 225 ) to be opened and closed smoothly.
With reference to FIGS. 4 , 5 A and 5 B, the drawer assembly ( 18 ) is mounted detachably on the bottom surface of the desktop ( 16 ), and has two side drawer panels ( 181 ), a rear drawer panel ( 182 ), and a drawer ( 185 ). The two side drawer panels ( 181 ) are mounted parallelly to the pedestal ( 12 ) and detachably onto the bottom surface of the desktop ( 16 ) using clasp connectors and at least one dowel ( 1221 ).
The rear drawer panel ( 182 ) is detachably mounted between the side drawer panels ( 181 ) using clasp connectors.
The drawer ( 185 ) has two side surfaces being slidably mounted between the side drawer panels ( 181 ) and two drawer rails ( 1812 ). The drawer rails ( 1812 ) are mounted respectively on the side surfaces of the drawer ( 185 ) and the side drawer panels ( 181 ) to allow the drawer ( 185 ) to open and close smoothly.
With reference to FIGS. 3A and 3B , the door ( 126 ) has an outer edge and multiple hinges ( 1263 ). Each hinge ( 1263 ) is mounted pivotally on the outer edge of the door ( 126 ) and the corresponding pedestal side panels ( 122 ) to allow the door ( 126 ) to rotate with respect to the pedestal side panel ( 122 ) and comprises two leaves. One leaf has a barrel and the other leaf has a pintle. The pintle is detachably mounted in the barrel.
The pedestal shelf ( 127 ) is mounted detachably in the hole pairs of the inner surfaces of the pedestal side panels ( 122 ).
By altering where the pedestal drawers ( 225 ), the drawer assembly ( 18 ), the door ( 126 ), the shelf ( 127 ) and the stand ( 14 ) are mounted, various orientations of the desk can be realized, allowing the person to customize the desk to their requirements. In a first embodiment of the present invention, a longer desk assembly ( 10 ) comprises the stand ( 14 ), drawer assembly ( 18 ), door ( 126 ) and shelf ( 127 ), whilst a shorter desk assembly ( 10 ) comprises two pedestal drawers ( 225 ) and is attached to the longer desk assembly ( 10 ).
With further reference to FIG. 10 , in a second embodiment, the longer desktop ( 16 ) comprises the stand ( 14 ), two pedestal drawers ( 225 ) and the drawer assembly ( 18 ), while the shorter desktop comprises the door ( 126 ) and the shelf ( 127 ). Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only. 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 ready-to-assemble (RTA) modular desk has multiple clasp connectors, two desk assemblies a door and at least one pedestal drawer. Each desk assembly has a pedestal, and a desktop having a bottom surface. The pedestal and a stand are constructed and mounted detachably on bottom surface of the desktop by using the clasp connectors. The desk assemblies are connected detachably to the each other using multiple latch assemblies. The door is mounted detachably on one of the pedestals. The pedestal drawers are mounted detachably in one of the pedestals. Therefore, the RTA modular desk can be assembled without using tools in a variety of orientations, allowing a person to customize the RTA modular desk to their needs and easily change or disassemble the RTA modular desk without using tools.
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BACKGROUND OF THE INVENTION
This invention relates to an inductive angle sensor for a motor vehicle.
Potentiometers are still primarily used in motor vehicles as position sensors, specifically for determining displacement angles of motor controlled or regulated elements. Their advantage, namely that they are particularly inexpensive, is offset by the disadvantages of sensitivity to dirt accumulation and wear.
To avoid these disadvantages, increasing use is being made of non-contact angle sensors that operate according to magnetoresistive, capacitative, or inductive principles.
According to such a principle, an inductive angle sensor comprises an excitation coil with alternating current applied thereto, a magnetic field of which induces voltage in one or more receiving coils; an amplitude or phase relationship of this voltage being dependent upon a position of an inductive coupler that is movable relative to the coils.
Particularly in critical safety applications in motor vehicles, such as in determining an angular position of a throttle valve that can be adjusted by motor, redundant measuring sensors are provided for safety reasons. When a potentiometer is used as a sensor, a redundant measuring sensor can thus be designed simply as a double potentiometer.
A design of a redundant measuring inductive angle sensor is, however, problematic since a positioning of two inductive sensor systems in close proximity can result in mutual interference of the sensor system, particularly through overlapping magnetic fields generated by the exciting coils.
Consider an example of a redundant inductive angle sensor comprising two complete and independent sensor systems, up to an inductive coupling element whose position is to be sensed. If two sensor systems that are largely identical in design are used for this purpose, i.e. having two oscillators that apply alternating current of identical frequency on the exciting coils, beats occur, even at extremely low frequency deviations, in signals of the receiving coils, making evaluation of the receiving coil signals extremely difficult or even impossible.
One conceivable solution is to select extremely different oscillator frequencies so that possible difference frequencies can readily be filtered out. However, this would mean that the oscillator and the evaluation circuit, which can be advantageously combined respectively into one circuit, would have to be designed differently for the two sensor systems, which doubles development expenses. Additionally, a cost of producing two different circuits with a same number of pieces would be significantly higher than that of producing one switching circuit with twice the number of pieces.
Therefore an object of this invention is to provide a redundant inductive angle sensor that can be manufactured in a simple and most inexpensive manner and that excludes mutual interference between the sensor systems.
SUMMARY OF THE INVENTION
According to principles of this invention an inductive angle sensor for motor vehicles has two oscillators with at least approximately identical oscillation frequencies, at least one excitation coil allocated to each oscillator, at least one receiving coil allocated to each oscillator, and at least one inductive coupling element, wherein the oscillators are structured as LC oscillation circuits and are inductively coupled to each other via the exciting coils.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described and explained in more detail below using an embodiment shown in the drawing. The described and drawn features, in other embodiments of the invention, can be used individually or in preferred combinations. The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating principles of the invention in a clear manner.
FIG. 1 shows a sketch of a layered printed circuit board for an inductive angle sensor of this invention; and
FIG. 2 shows a sketch of one of the layers of the layered printed circuit board shown in FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows one level of a multi-layer printed circuit board 7 , but not all electrical connections specified below are immediately visible in the figure because multiple connections are formed between levels 9 of the printed circuit board by feedthroughs 8 (shown as dot elements at the ends of conductor strips). However, this is insignificant for explanation of structural principles of the inductive angle sensor of the invention as described below.
Also not shown is an inductive coupling element, which may be realized as a metallic element, short circuit coil, or similar element, the angular position of which is detected by the angle sensor relative to a coil arrangement on the printed circuit board.
The inductive angle sensor comprises two galvanically independent but inductively coupled sensor systems. Each sensor system comprises respectively one integrated circuit 1 , 2 and an exciting coil 3 , 4 as well as several receiving coils 11 , 12 (FIG. 2) that form periodic, or spaced, structures (e. g. meandering, triangular structures) on various printed circuit board levels within a circumference of the circular conductor strips. Coupling leads 5 , 6 of these receiving coils 11 , 12 (in the example shown, there are five per sensor system) lead to the circuits 1 , 2 , each of which contains an evaluation circuit for evaluating the receiving coil signals.
The evaluation circuit determines a precise angular position of the inductive coupling element from the various amplitude values and phase relationships of the receiving coil signals.
Also integrated with the circuits 1 , 2 are oscillator circuits that apply alternating current to the exciting coils 3 , 4 , respectively. These oscillator circuits are inventively structured as “soft” LC oscillators, oscillation frequencies of which can be changed by external influence over a preset frequency range, without resulting in any unstable oscillating behavior or holes, or breaks, in the oscillations.
The inductive component of each LC oscillator is formed by the corresponding exciting coil 3 , 4 . Because of the close proximity of the exciting coils 3 , 4 to each other, the oscillators experience an inductive coupling such that oscillations having identical frequencies and phases are created in both oscillators. The common oscillation frequency can diverge from the frequencies that each individual oscillator would have generated without influence.
The inductive angle sensor, therefore, solves the problem of frequency-accurate oscillators exhibiting slight variations from a predetermined base frequency. If two fixed-frequency oscillators, e. g. quartz oscillators, generate alternating fields having only approximately identical frequencies, undesirable effects occur, specifically beats of the difference frequency between the two oscillators, which makes it difficult or even impossible to evaluate the angular position of the inductive coupling element from signals output by the receiving coils.
An additional, albeit less advantageous, solution would be to provide oscillators having significantly different oscillation frequencies, so that difference frequencies are not disturbing or can be filtered out easily. However, since the circuits would have to be designed significantly differently from each other for generating the oscillations and for evaluating the signals, this solution would be considerably more expensive.
Another solution would be to provide only one oscillator that drives both exciting coils. However, this solution does not correspond to the need for creating a fully redundant angle sensor that has two sensor systems functioning independently of each other. With only one oscillator, a failure of that oscillator also means failure of the entire angle sensor.
Therefore, an angle sensor according to this invention, having two self-synchronizing oscillators, seems especially advantageous in terms of expense and operational reliability.
The idea of the invention is based on providing two oscillators that are designed as LC oscillators coupled to each other via the exciting coils. LC oscillators can be made “soft”, or “flexible”, i.e. capable of being tuned within a specific frequency range, without its oscillation behavior becoming unstable or having holes, or breaks, in the oscillations.
Because the two oscillators are coupled, they oscillate at the same frequency and phase relationship, whereby harmful beating can be prevented in a surprisingly easy manner.
Furthermore, it is advantageous that LC oscillators are extremely inexpensive, because the exciting coils form the inductors of the LC oscillation circuits and, also, additional frequency stabilizing devices (quartz) can be omitted.
It is also advantageous that a “tuning range” of an oscillator frequency can be preset by dimensioning oscillator components. Specifically dissipative elements of components employed make Q-factors of the oscillators so low that the oscillators still function stably within a deviation range of at least ±1 kHz of a base frequency when their oscillation frequencies are modified by external influence.
Because of the mutual coupling of the oscillators via the exciting coils, it is not only possible to, but also advantageous to, position the two exciting coils in close proximity to each other, indeed in an advantageous manner on a printed circuit board.
For this, the individual exciting coils can be structured, for example, as spiral-shaped or concentric conductor strips, and positioned concentrically with respect to each other.
Furthermore it is advantageous to provide a multi-layer printed circuit board as a printed circuit board on which the receiving coils, 11 , 12 also structured as conductor strips, and circuits for generating oscillations and for evaluating signals are positioned.
It is advantageous for the two sensor systems to be inductively coupled, but galvanically separate, so that if one sensor system should fail, the second remains functional. This leads to the advantageous embodiment in which all electrical components up to the excitation and receiving coils are combined respectively into a single electrical circuit. Because the same circuit can be used twice in the structure of the inductive angle sensor of this invention, it can be manufactured in larger numbers, and thus in a particularly inexpensive manner.
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A redundant inductive angle sensor has two LC oscillators of at least approximately identical design. By inductively coupling the oscillators, the oscillators synchronize themselves with respect to frequency and phase relationship so that undesirable mutual interference is prevented. This provides an inductive angle sensor, which is able to function even if one of the LC oscillators becomes inoperative.
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This is a continuation of application Ser. No. 08/062,605, filed May 17, 1993, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to an applicator system for application of color coating on a paper web. The system may include both roll type and nozzle type applicators.
Roll applicators of this type are known from DE 36 05 409 A1. This device is intended to produce a uniform coating.
The technical requirements for coating systems, more generally, are always the following: the coating is to be applied on the paper web uniformly in any respect, and at that, both in cross direction (cross profile) and also in longitudinal direction. The primary concern is the coating weight, but also other properties such as the outer appearance of the coating surface.
The disturbance factors opposing these requirements are numerous. With roll type applicator systems, problems occur most of all in the wedge-shaped entrance zone between applicator roll and backing roll, and at that, especially at high velocities. This is attributable most of all to the effect of the air which in the rotation of the backing roll is carried into the entrance bore together with the paper web. The air mixes with the color coating at the point where the latter makes contact with the paper web. Generally, an overflow of color coating occurs at the upper edge of the machinewide guide assembly, and at that, opposite to the direction of travel of the paper web and opposite to the airflow. If the airflow impinges on this overflow, the result is a partial backup of the overflow as well as a mixing of air and color coating. Disturbances of that type occur also in the absence of a guide assembly, when as a consequence an unimpeded level of coating mixture adjusts itself between the shell surface of the applicator roll and the wall of the trough.
Another disturbance factor may be constituted by an irregular supply of color coating to the application zone. These irregularities may have various causes, for instance manufacturing inaccuracies of the participating components, shortcomings in the design geometry or flow geometry, or hydrodynamic disturbance problems, and thus undesirable variations of the dimensions of the flow channels in which the color coating flows.
A third category of disturbance factors resides in the base paper. As is generally known, the base paper involves fluctuations of the basis weight, roughness and absorption performance, and at that, both across the web width and also in the travel direction of the web, and thus over time. These factors are particularly difficult to manage.
As known, doctor systems are located at the end of the usual roll type applicators. These systems comprise a doctor blade, which can be set at the paper web bearing on the backing roll, and a doctor beam supporting the blade. In the event of coating irregularities, corrections are attempted by means of the doctor system. In doing so, an adjustment can be effected across the entire width. But locally limited corrections can also be made, that is, only at certain points of the web width. These measures may provide a certain remedy, but mostly they are insufficient to achieve the desired result.
The problem underlying the invention is to design an applicator system in such a way that the coating may in any respect be produced more uniformly than was the case previously.
SUMMARY OF THE INVENTION
The present invention overcomes the problems and disadvantages of the above described prior art systems by including a control means for controlling the color coating by measuring a predetermined quality of the color coating at several points along the width of the paper to be coated and then controlling the applied color coating in a zonewise fashion across the width of the paper. The basic idea of the invention consists in performing a zonewise influencing of the coating, or of its properties, by means located at a certain distance before the application zone. The means operate zonewise--i.e., across broad sections of the machine--to influence particular qualities of the color coating either the throughput of color coating or its temperature or its consistency or viscosity.
With prior applicator systems, measures were always directed at influencing the disturbance factors themselves, and thus the coating. The inventor now has chosen an entirely different avenue: he is not concerned with the disturbance factors themselves. He rather utilizes the measuring data of the finished coating in order to exert by the said measures--changes of throughput, temperature or consistency--an influence at a much earlier point. This principle has proved to be an elegant, cost-saving and effective way to compensate for the disturbance factors.
There are many options in reducing the invention to practice. For example, the flow channel formed between the applicator roll and the guide wall may at a specific point of the flow path feature a plurality of valves arranged side by side across the channel width, for instance in the form of constrictors. A zonewise influencing of the throughput in the channel then takes place by appropriate actuation of one or several of these valves. Furthermore, it would be conceivable to provide again at a specific point in the flow path a plurality of outlets. Opening or closing one or several of these outlets changes the color coating throughput across a specific zone. Additionally, instead of the outlets, feed lines could be provided which are adjustable by the valves and which--again at a specific point in the flow path--empty into the channel, distributed across its width.
Instead of the measures influencing the throughput, it is according to the invention, also possible to influence the temperature. To that end, a number of heating elements can be arranged, distributed across the width of the machine. They may be arranged either in the flow channel between the applicator roll and the guide wall or within the (hollow) applicator roll, or at any other point in the wall of the trough holding the color coating sump.
Lastly, a number of feed lines can be provided which--again distributed across the width--are able to supply dilutants for the color coating.
All of the above measures are applied in accordance with the result of the data measured on the finished coating. These measuring data thus serve as measuring signals which are entered in a CPU, which issues the instruction to the respective correction unit, for instance, in the case of consistency control, to selected dilutant feed lines.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a side elevation of a roll applicator system;
FIG. 2 is a detail of the object of FIG. 1, and at that, in the direction of view of arrow A;
FIG. 3 is a second embodiment of a roll applicator system, again in side elevation;
FIG. 4 is a third embodiment of a roll applicator system, again in side elevation;
FIG. 5 is a perspective illustration of a detail of the object of FIG. 4;
FIG. 6 is a fourth embodiment of a roll applicator system, again in side elevation;
FIG. 7 is a detail of the object of FIG. 6, and at that, as a plan view in the direction of arrow A;
FIG. 8 is a fifth embodiment of a roll applicator system in side elevation;
FIG. 9 is a sixth embodiment of a roll applicator system in side elevation;
FIG. 10 is a section of the object of FIG. 9, but viewed in axial section;
FIG. 11 is a seventh embodiment of a roll applicator system in side elevation;
FIG. 12 is an eighth embodiment of a roll applicator system in side elevation;
FIG. 13 is a ninth embodiment of a roll applicator system in side elevation;
FIG. 14 is a detail of the object of FIG. 1, viewed in the direction of arrow A.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
The roll applicator system illustrated in FIG. 1 features an applicator roll 1 rotating in a color coating sump 2 contained in a trough 3. Visible, additionally, is a backing roll 4 around which loops a paper web 5. The trough 3 features an overflow edge 6, across which a first overflow --opposite to the direction of travel of the paper web 5--can flow into a first overflow chute 7, where the overflow is removed.
Moreover, there is a nozzle applicator system 8 which follows the roll applicator system. Thus another embodiment is a combined roll-nozzle applicator system. A deflector plate 9 guides a second overflow--coming from the nozzle applicator system--into a second overflow chute 10.
The elements decisive for the invention are embodied in the distributing system. They are visible particularly well in FIG. 2. The distributing system comprises first a conical distribution pipe 20 featuring on its one end an inlet 21 and on its other end an outlet 22. Arranged essentially parallel to the distribution pipe 20 is a feed pipe 23. Feed pipe 23 connects via a number or connecting lines 24 to the distribution pipe 20. The connecting lines 24 feature valves 25. The feed pipe 23 borders on the color coating sump 2 and communicates with it through discharge bores 26.
Decisive in the sense of the invention in this embodiment is the design of the distribution system. Visible in FIG. 1, in the upper area of the connecting lines 24, are electrical heating rods 27, that are coordinated with each individual connecting line. These heating rods can be activated separately, so at least one connecting line or several of these connecting lines 24 can be heated. The heating depends on the result of the measuring system 80, which follows the entire applicator system and which, expressed more generally, captures the quality or a property of the coating (coating profile measurement).
Instead of using heating rods 27 it is also possible to encase the individual connecting lines 24, so each is surrounded by a chamber to which hot water or steam may be fed.
In the embodiment according to FIG. 3--showing again a combined roll-nozzle applicator system--the feed pipe 23 is fashioned as a cylindrical or conical pipe. It assumes thus simultaneously the function of the distribution pipe 20 in the embodiment according to FIG. 1 and 2. This feed pipe 23 receives in this embodiment on the one end a color coating of "nominal composition." The color coating discharges through discharge bores 26 and thus proceeds into the sump 2 contained in the trough 3. As the case may be, any surplus issues out of the other end of the feed pipe 23, controlled again by a valve.
Unique on this embodiment is that the feed pipe 23 may be supplied, through a number of lines 24 featuring valves 25, with a color coating or dilutant of a different composition or different consistency or different viscosity or temperature other than that of the color coating, which in "nominal composition" is supplied to the distribution pipe 23 on its end. Also thereby, of course, a zonewise influence can be exerted on the coating quality, thus achieving a coating profile control.
In the embodiment according to FIGS. 4 and 5, the feed pipe 23 is again provided with discharge bores 26 which empty into the sump 2.
Decisive here is that in the sense of the invention, a zonewise control can be performed by adjusting the flow cross section of the discharge bore 26, such as by means of valves. Illustrated in FIG. 5 is a valve assembly 30 which interacts with a discharge bore 26 as a valve seat, additionally a valve tappet 31, a valve piston 32 and a cylinder 33. The piston-cylinder unit can presently be actuated pneumatically. Of course, such regulating valves can be activated also by control motors. This feed pipe 23, too, assumes at the same time the function of the distribution pipe according to FIG. 1. It has on the one end an inlet and on the other end a controlled outlet. It may be both cylindrical and conical.
The embodiment according to FIGS. 6 and 7 shows another peculiarity. Visible at the point I, in the flow path of the color coating between the applicator roll 1 and the wall of the trough 3, is a constrictor 40, which is only one of many which--as viewed in the axial direction of the applicator roll--are arranged successively. The constrictor features a bellows 41 which can be pushed or rolled into the flow path, thereby reducing the available flow cross section. A pneumatic unit 42 may again provide the drive.
A quite analogous system 43 may be provided at the point II. This arrangement is especially favorable, since thereby a guide assembly 44 is simultaneously utilized which forms a controlled flow channel 45 for a controlled overflow to a first overflow chute 7. It is understood that the constrictors 40, 44 may be provided either by themselves or separately.
In the embodiment according to FIG. 8, the applicator roll is fashioned after a flexure compensator roll. Here, the applicator roll 1 comprises a stationary yoke 50, a rotating shell 51 which is essentially concentric to it, as well as a number of plungers 52 which in controlled fashion produce a bearing between the yoke 50 and the shell 51. With this setup, zonewise corrections of the coating result can be achieved as well, depending on which plungers are activated.
The embodiment according to FIGS. 9 and 10 approaches the problem essentially at the same place as that according to FIG. 8. But here, activatable magnetic field systems serve the exertion of thrust forces and, thus, the deformation of the roll shell 51. FIG. 10 depicts permanent magnets 60 arranged on the backing roll 4, as well as soft iron cores 61 with coils coordinated with the applicator roll 1. This embodiment compared to the one relative to FIG. 8, has the advantage of being simpler and less expensive in design and that the adjustment of the application gap can be carried out more sensitively.
A quite significant embodiment is illustrated in FIG. 11. Here, the distance a is electrothermally varied zonewise with the aid of induction coils 70. The advantage of this embodiment is that, by means of the induction coils, the spacing can be held extremely close, namely at values of less than 100 mm. Additionally, the induction current allows an extremely sensitive control, making the zonewise control precise and reproducible.
This principle also can be provided anywhere in the flow path of the color coating. Thus, the induction coils may serve to adjust the channel width between the applicator roll 1 and the trough 3 for example.
In the embodiment according to FIG. 12, the zone control is again effected by means of temperature. Here, the trough 3 is heated zonewise as viewed in the axial direction of the applicator roll 1, but may be heated differently as the case may be. The heating may be performed with electrical heating rods, by hot water, steam, by inductions coils or other means.
In the embodiment according to FIG. 13 and 14, the steam heating concept is illustrated in more detail. Visible in the side elevation according to FIG. 13 is a chamber 70 featuring a steam socket 71 with a valve 72. FIG. 14 shows a number of chambers 70 are included in this embodiment.
While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.
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An applicator system for applying color coating on a paper web is disclosed having a color coating applicator along with a backing roll around which is wrapped the paper web. A measuring system is incorporated for measuring a predetermined property of the color coating at several points along the width of the paper web. Predetermined qualities of the color coating include weight, thickness, or surface properties of the coated surface. A control means is included for controlling the color coating arriving at the application zone. The color coating is controlled by varying the temperature, or the consistency of the color coating in a zonewise fashion across the width of the paper web.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to computer system networks, and more particularly to networked personal computer systems. Still more particularly, this application relates to the use of Universal Serial Bus based communications for computer networking.
2. Description of the Prior Art
Computer networking is, and has been for some years, common in, the industry. The ability to connect many computer systems in a network, whether as server/client or peer-to-peer, has become an indispensable tool to business, and has recently begun to enter users' homes. To make computer networking available to as many people as possible, it is desirable to make these networks as easy to set up and operate as possible.
Current networking equipment generally consists of a network interface card (NIC), which is installed in each computer system, then connected to other computer systems. Even the installation of the NIC is beyond the abilities of most computer users, since it generally entails actually opening the computer system chassis and physically installing the NIC on the system board.
Each NIC must then be connected either to a network hub, which allows many systems to be networked in a “hub and spoke” arrangement, or directly to one or more other systems in a daisy-chain arrangement. Each system must then be configured to communicate with each other system, using appropriate operating-system drivers. Other equipment, such as a printer, may then be attached to the network, and shared between the computer systems on that network.
Because of the relative complexity of setting up a computer network, it is beyond the ability of most individuals or small businesses, unless they are willing and able to take on the cost of hiring a technician to do the installation. It would therefore be desirable to achieve a means of networking computer systems and equipment that is as easy as possible.
The Universal Serial Bus (USB) specification describes a cable bus that supports data exchange between a host computer and a wide range of simultaneously accessible peripherals. The bus allows peripherals to be attached, configured, used, and detached while the host and other peripherals are in operation; i.e., the peripherals are “hot swappable.” Because most personal computer systems now include an installed USB port, users are able to simply plug in any number of peripherals to the host computer system, allowing a wide range of devices to be easily attached and detached.
The host computer system is the system where the-USB Host Controller is installed. This includes the host hardware platform (CPU, bus, etc.) and the operating system in use; this is generally the only actual computer system present, with all other attached USB devices being either USB hubs or peripheral devices for that computer system. It is important to note that the USB specification, available at http://www.usb.org and hereby incorporated by reference, requires that only one host be present in any USB system.
A USB system has three primary types of devices, the USB host, described above; one or more USB devices, such as printers, scanners, and modems; and the USB interconnect, which is the manner in which USB devices are connected to and communicate with the host. The interconnect includes the Bus Topology, the Inter-layer Relationships, Data Flow Models, and the USB Schedule. The details of the interconnect, and device and host requirements, may be found in the USB specification, and is not of concern to the average user.
Because of the ease of using USB connections and devices for the average user, it is a preferred means of implementing many communications between computer systems and devices. Since the USB specification requires that there is only one USB host in any system, however, USB has not been available for use in networking multiple computer systems. Therefore, it would be desirable to provide a means for combining the ease-of-use of a USB system into a computer networking system, to provide an improved computer networking system that is technically accessible to most users.
SUMMARY OF THE INVENTION
It is therefore one object of the present invention to provide an improved computer system network.
It is another object of the present invention to provide an improved system and method for personal computer networking.
It is yet another object of the present invention to provide an improved system and method for personal computer networking utilizing Universal Serial Bus based communications.
There is therefore provided a system and method for providing network communications between personal computer systems using USB communications. The disclosed USB networking hub allows multiple hosts to exist in a USB-based network. The networking hub includes an integrated virtual network adapter, which provides for communications among and between multiple hosts.
The above as well as additional objectives, features and advantages of the present invention will become apparent in the following detailed written description.
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 objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a block diagram of a data processing system in accordance with the preferred embodiment of the present invention;
FIG. 2A depicts a block diagram of a networking hub in accordance with the preferred embodiment of the present invention;
FIG. 2B depicts a block diagram of a networking hub in accordance with an alternate embodiment of the present invention;
FIG. 3 is a more detailed block diagram of a virtual network adapter in accordance with a preferred embodiment of the present invention;
FIG. 4 depicts a flowchart of the initialization process of the virtual network adapter in accordance with a preferred embodiment of the present invention; and
FIG. 5 is a flowchart of a data transmission routine in accordance with a preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description details the operation and features of several preferred embodiments of the present invention, but it will be understood by those of skill in the art that the scope of the invention is defined only by the issued claims, and not by any description herein.
With reference now to the figures, and in particular with reference to FIG. 1, a block diagram of a data processing system in which a preferred embodiment of the present invention maybe implemented is depicted. Data processing system 100 may be, for example, one of the desktop models of personal computers available from International Business Machines Corporation of Armonk, N.Y. Data processing system 100 includes processors 101 and 102 , which in the exemplary embodiment are each connected to level two (L2) caches 103 and 104 , respectively, which are connected in turn to a system bus 106 .
Also connected to system bus 106 is system memory 108 and Primary Host Bridge (PHB) 122 . PHB 122 couples I/O bus 112 to system bus 106 , relaying and/or transforming data transactions from one,bus to the other. In the exemplary embodiment, data processing system 100 includes graphics adapter 118 connected to I/O bus 112 , receiving user interface information for display 120 . Peripheral devices such as nonvolatile storage 114 , which may be a hard disk drive, and keyboard/pointing device 116 , which may include a conventional mouse, a trackball, or the like, are connected via an Industry Standard Architecture (ISA) bridge 121 to I/O bus 112 . PHB 122 is also connected to PCI slots 124 and USB controller 126 via I/O bus 112 .
The exemplary embodiment shown in FIG. 1 is provided solely for the purposes of explaining the invention and those skilled in the art will recognize that numerous variations are possible, both in form and function. For instance, data processing system 100 might also include a compact disk read-only memory (CD-ROM) or digital video disk (DVD) drive, a sound card and audio speakers, and numerous other optional components. All such variations are believed to be within the spirit and scope of the present invention. Data processing system 100 and the exemplary networking hubs described below are provided solely as examples for the purposes of explanation and are not intended to imply architectural limitations.
Referring now to FIG. 2A, the networking hub 200 includes multiple sub-hubs, 202 , 204 , 206 , each of which has an associated virtual network adapter (VNA) 210 , 212 , 214 , respectively. Each sub-hub is connected to a single upstream host at host connections 220 , 222 , 224 , and is connected to one or more USB devices on ports 230 , 232 , 234 . It is noted that the USB specification refers to USB peripheral devices as “functions,” and the terms “device” and “function” will be used interchangeably here. Each sub-hub allows communications, in a conventional manner, between its respective upstream host and devices attached to its ports. Although, in this exemplary diagram, only one port is shown attached to each sub-hub, those of skill in,the art will realize that each sub-hub can support multiple ports.
The respective VNAs 210 , 212 , 214 of each sub-hub are interconnected over logical interconnect 240 to provide for communications among and between each sub-hub. By communicating over the VNA system, communications are provided between the multiple hosts. Each sub-hub can accommodate a single upstream connection, a single VNA, and one or more downstream connections. It should be noted that upstream connections 220 , 222 , 224 , need not be directly to a host, but may be connected, for example, over a series of interconnected USB hubs.
The VNA system is provided to overcome one limitation of the USB specification, which requires that only one host can connect to each USB system. The VNA 210 , 212 , 214 appears to each host, in the preferred embodiment, as an ethernet adapter attached to its respective sub-hub 202 , 204 , 206 . Each host therefore is able to communicate with each other sub-hub, and with the nodes and devices attached to the other sub-hubs, by communicating over the VNAs of the respective sub-hubs.
With reference now to FIG. 2B, an alternate networking hub 250 is provided, in which a single VNA controller 260 manages communications between each sub-hub 252 , 254 , 256 . This embodiment, which appears to the hosts and USB devices to be functionally identical to the embodiment of FIG. 2A, reduces needless duplication of logic by combining the functions of multiple VNA controllers 210 , 212 , 214 into a single VNA controller 260 . The single VNA appears to each sub-hub as its own dedicated network device.
This system operates as above, allowing hosts on upstream attachments 270 , 272 , 274 communicate via sub-hubs 252 , 254 , 256 , respectively, to USB devices on ports 280 , 282 , 284 . VNA 250 allows communications between the sub-hubs, so that each host can effectively communicate with other hosts. Inter-VNA module 286 and inter-hub VNA connection 288 allow multiple networking hubs to be interconnected.
Referring now to FIG. 3, a more detailed block diagram of an exemplary VNA 300 is shown. VNA 300 is a single VNA with multiple sub-hub inputs, as shown in FIG. 2 A. USB I/F blocks 330 , 340 , 350 are USB interface connections for the USB sub-hubs which the VNA interconnects. These are connected to microcontroller 310 , which manages VNA communications. The VNA firmware 370 is preferably stored in a non-volatile FLASH memory. Random access memory 360 is used asa buffer and scratchpad memory.
The inter-VNA port 380 is an optional port used to connect directly to another VNA. In the preferred embodiment, communications over this port are standard serial communications, and a standard null-modem cable can be used to connect multiple VNAs. Of course, if a higher bandwidth is desired, this port can be implemented with any number of high-speed interconnects.
The USB I/F (VNA) block 320 is an optional dedicated USB port for the VNA to act as a USB “function” or device. This may be used for a USB host to communicate directly with the VNA, for example to update the VNA firmware.
In reference to FIG. 4, a flowchart detailing the initialization sequence of the network hub is shown. Upon startup (step 410 ), the VNA microcontroller initializes and enables the USB interfaces to be recognized and attached by any attached sub-hubs (step 420 ). The connected sub-hubs then recognize the VNA and attach it as a USB function (step 430 ). After this, when the host queries the sub-hub over its USB upstream connection (step 440 ), the sub-hub indicates the VNA as an attached USB function (step 450 ). The host then attaches the VNA as a USB/Network function (step 460 ), since it sees the VNA as a network adapter attached to the USB sub-hub. The host then loads an appropriate network driver for the VNA (step 470 ), and the initialization routine ends (step 480 ).
With reference now to FIG. 5, a flowchart showing the VNA data transport routine is shown. When the system is operating (step 510 ), the VNA microcontroller will receive a data packet from a host via the sub-hub over one of its USB interfaces (step 520 ). This data packet is buffered in the VNA RAM (step 530 ), then sent out to the destination sub-hub (step 540 ). It should be noted that when the data packet is resent out, the VNA controller will rebroadcast this packet only to the non-originating USB interfaces; this prevents the originating sub-hub from receiving the resent packet broadcast. Next, if the inter-VNA port is enabled (step 550 ), the data packet is also sent out over the inter-VNA connection (step 560 ). Finally, when all broadcasts have completed, the VNA RAM,buffer is cleared (step 570 ) and the routine ends (step 580 ).
While the invention has been particularly shown and described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. For example, while the above description discusses is specifically drawn to the Universal Serial Bus specification, the disclosed networking system and virtual network adapter can be modified to any number of communications standards and different computer architectures and systems. Other variations are certainly within the ability of one skilled in the art, and are expected to fall within the scope of the claims.
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A system and method for providing network communications between personal computer systems using USB communications. The disclosed USB networking hub allows multiple hosts to exist in a USB-based network. The networking hub includes an integrated virtual network adapter, which provides for communications among and between multiple hosts.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a construction of a radiation image taking apparatus that uses a radiation detection means. In particular, the present invention relates to a technique suited for the designation of an image taking direction of an object with respect to a radiation image taking apparatus.
[0003] 2. Related Background Art
[0004] Conventionally, a film/screen method, with which radiation image taking is performed by combining a photosensitive film (X-ray detection means) serving as a two-dimensional detection plane with a phosphor having sensitivity to X rays, has been most commonly used to take an X-ray image. In addition, in recent years, a method called “computed radiography (CR) method” has also been put into practical use. This method is a system where a radiation transmission image is first accumulated as a latent image in an imaging plate serving as a two-dimensional detection plane and then the latent image is read out from the imaging plate by irradiating excitation light onto the imaging plate. Aside from this, with the recent advancement of a semiconductor process technique, an apparatus has also been developed which takes an X-ray image in a like manner using an X-ray detection sensor composed of multiple photoelectric conversion elements as a two-dimensional detection plane. A system of this type has an advantage that it is possible to record an image having an extremely wide radiation exposure range as compared with the conventional radiograph system using a photosensitive film. That is, after X rays in a wide dynamic range are read with the X-ray detection sensor and are converted into an electrical signal, a radiation image is outputted as a visible image to a recording material (such as a photosensitive material) or a display apparatus (such as a CRT) using the electrical signal, thereby making it possible to obtain a radiation image that is hard to be influenced by variations in radiation exposure amount.
[0005] FIG. 22 is a schematic diagram showing a radiation image taking system that uses the semiconductor sensor described above. In an X-ray image taking apparatus 2201 , an X-ray detection sensor 2202 is embedded which has a detection plane where multiple photoelectric conversion elements are arranged in a two-dimensional manner. With this construction, X rays emitted from an X-ray generation portion 2203 are irradiated onto an object 2206 and X rays transmitted through the object 2206 are detected by the X-ray detection sensor 2202 . An image signal outputted from the X-ray detection sensor 2202 is subjected to digital image processing in an image processing means 2204 and is displayed on a monitor 2205 as an X-ray image of the object 2206 . Such an X-ray detection sensor is called “planar detector”, “flat panel”, or the like due to its shape.
[0006] When image taking is performed with the various systems described above, in order to position the object in a detection area of the detection means, it is required to indicate the detection area of the detection means and the like on the enclosure of the planar detector. A method for displaying the detection area of the detection means on the enclosure of the planar detector is proposed in Japanese Patent Application Laid-Open No. 2002-291730.
[0007] FIG. 23 shows an example of a conventional transportable planar detector. In this drawing, reference numeral 2301 denotes a transportable X-ray image taking apparatus in which an X-ray detection sensor (not shown) is embedded which has a detection plane where multiple photoelectric conversion elements are arranged in a two-dimensional manner. Reference numeral 2302 indicates a cover for an enclosure plane of the X-ray image taking apparatus 2301 in a portion where X rays are irradiated, with the cover being made of a material having a high X-ray transmittance and being a carbon plate or the like. Reference numeral 2303 represents a rectangular frame line representing the detection plane of the X-ray detection sensor (not shown). Reference numeral 2304 denotes a center line in a short-side direction of the rectangular detection plane and reference numeral 2305 indicates a center line in a long-side direction thereof. Reference numeral 2307 represents a cable connecting the X-ray image taking apparatus 2301 to a control apparatus (not shown), with electrical signals that are control signals and an electronic image being communicated between the X-ray image taking apparatus 2301 and the control apparatus through the cable. Reference numeral 2308 denotes an object, with a case where the object 2308 is a right hand of a person being illustrated in the drawing as an example. In FIG. 23 , the upper left corner of the frame line 2303 is set as the image coordinate original point of the X-ray detector (not shown). Also, in the drawing, the downward direction is set as the positive direction of an X axis and the rightward direction is set as the positive direction of a Y axis.
[0008] FIG. 24 is an explanatory diagram of a case where an image taken with the X-ray image taking apparatus 2301 is displayed on a monitor 2401 . In this drawing, reference numeral 2403 denotes an object and reference numeral 2402 indicates an image area. In this illustrated case, a definition has been formulated in advance so that an image coordinate original point is positioned at the lower left corner of the display apparatus.
[0009] FIG. 25 shows a case where the same X-ray image taking apparatus 2301 as in FIG. 23 is set under a state where it has been rotated by 180°. The same reference numerals as in FIG. 23 denote the same members. In this drawing, the image original point is changed to the lower right corner, although the cover 2302 , the frame line 2303 , and the center line 2304 have symmetric shapes and therefore are not changed from their states shown in FIG. 23 . Consequently, if image taking is performed by determining the detection plane for the object 2308 in the same direction as in FIG. 23 without giving consideration to the fact that the X-ray image taking apparatus 2301 has been rotated by 180°, image displaying on the monitor 2401 is performed in the manner shown in FIG. 26 where an object 2601 is displayed under a state where it has been rotated by 180° from the state of the object 2403 shown in FIG. 24 . That is, in this case, the object is not displayed in an original observation direction.
[0010] As described above, when image taking is performed using a transportable X-ray image taking apparatus or an X-ray image taking apparatus embedded in a bed, various relative positional relationships between the two-dimensional detection plane and the object are possible, which leads to a problem in that it is not guaranteed that a taken image is displayed in a desired direction at the time of image displaying. Also, there is a case where printing is performed by inserting an object name, an image taking date and time, and the like (hereinafter referred to as the “annotation”) in the upper portion or the like of an electronic image. In this case, there occurs a problem in that the positional relationship between the annotation and the object does not become a desired relationship at the time of displaying.
[0011] In the conventional example described above, even in the case shown in FIG. 26 where the image is displayed in a direction that is different from the original direction, it is possible to obtain the same positional relationship as in FIG. 24 by rotating the image, although this results in a situation where the convenience of the system, whose advantage lies in the immediacy of image displaying is lost. It is possible for an operator to define in advance the correspondence between the coordinate original point and the coordinate system of a taken image and a display portion of the display apparatus at the time of displaying, although it is usual that this correspondence is defined in units of parts to be image-taken. Therefore, when the same part is image-taken in different directions like in this example, there occurs a problem in that it is impossible to perform displaying in a desired direction without delay.
SUMMARY OF THE INVENTION
[0012] The present invention has been made in view of the problems described above, and is aimed at making it possible to designate the image taking direction of an object with respect to an X-ray image taking apparatus.
[0013] Other features and advantages of the present invention will be apparent from the following description taken in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
[0015] FIG. 1 is a perspective view illustrating a schematic construction of an X-ray image taking apparatus of a first embodiment of the present invention;
[0016] FIG. 2 is a perspective view illustrating an example of displaying on a monitor of the first embodiment;
[0017] FIG. 3 is a block diagram illustrating a schematic construction of a radiation image taking system using the X-ray image taking apparatus of the first embodiment;
[0018] FIG. 4 is a flowchart showing an operation procedure of the first embodiment;
[0019] FIG. 5 is a plan view illustrating the schematic construction of the X-ray image taking apparatus of the first embodiment;
[0020] FIG. 6 is another plan view illustrating the schematic construction of the X-ray image taking apparatus of the first embodiment;
[0021] FIG. 7 is an enlarged view of an indicator portion of an X-ray image taking apparatus of a second embodiment;
[0022] FIG. 8 is another enlarged view of the indicator portion of the X-ray image taking apparatus of the second embodiment;
[0023] FIG. 9 is a perspective view illustrating a schematic construction of an X-ray image taking apparatus of a third embodiment;
[0024] FIG. 10 is another perspective view illustrating the schematic construction of the X-ray image taking apparatus of the third embodiment;
[0025] FIG. 11 is a plan view illustrating a schematic construction of an X-ray image taking apparatus of a fourth embodiment;
[0026] FIG. 12 is a plan view illustrating a schematic construction of an X-ray image taking apparatus of a fifth embodiment;
[0027] FIG. 13 is a plan view illustrating a schematic construction of an X-ray image taking apparatus of a sixth embodiment;
[0028] FIG. 14 is a plan view illustrating a schematic construction of an X-ray image taking apparatus of a seventh embodiment;
[0029] FIG. 15 is a plan view illustrating a schematic construction of an X-ray image taking apparatus of an eighth embodiment;
[0030] FIG. 16 is a plan view illustrating a schematic construction of an X-ray image taking apparatus of a ninth embodiment;
[0031] FIG. 17 is a plan view illustrating a schematic construction of an X-ray image taking apparatus of a tenth embodiment;
[0032] FIG. 18 is a plan view illustrating a schematic construction of an X-ray image taking apparatus of an eleventh embodiment;
[0033] FIG. 19 is a plan view illustrating a schematic construction of an X-ray image taking apparatus of a twelfth embodiment;
[0034] FIG. 20 is a plan view illustrating a schematic construction of an X-ray image taking apparatus of a thirteenth embodiment;
[0035] FIG. 21 is a plan view illustrating a schematic construction of an X-ray image taking apparatus of a fourteenth embodiment;
[0036] FIG. 22 is an explanatory diagram of a conventional radiation image taking system;
[0037] FIG. 23 is a perspective view illustrating a schematic construction of a conventional X-ray image taking apparatus;
[0038] FIG. 24 is a perspective view illustrating an example of conventional displaying on a monitor;
[0039] FIG. 25 is another perspective view illustrating the schematic construction of the conventional X-ray image taking apparatus; and
[0040] FIG. 26 is a perspective view illustrating another example of the conventional displaying on the monitor.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] Preferred embodiments of the present invention will now be described in detail in accordance with the accompanying drawings.
[0042] The present invention will now be described in detail below based on embodiments illustrated in FIGS. 1 to 21 . In particular, in each following preferred embodiment, a case where X rays among radiation are used will be described.
[0043] FIGS. 1 to 6 each illustrate a first embodiment of the present invention. In these drawings, the same reference numerals denote the same members.
[0044] First, a construction of this embodiment will be described with reference to FIG. 1 . In this drawing, reference numeral 101 denotes a transportable X-ray image taking apparatus in which a X-ray detection sensor (not shown) is embedded which has a detection plane where multiple photoelectric conversion elements are arranged in a two-dimensional manner. Reference numeral 102 indicates a cover for an enclosure plane of the X-ray image taking apparatus, with this cover being made of a material having a high X-ray transmittance and being a carbon plate or the like. Reference numeral 103 represents a rectangular frame line expressing the detection area of the X-ray detection sensor (not shown). Reference numeral 104 denotes a center line in a short-side direction of the rectangular detection area. Reference numeral 105 indicates a center line in a long-side direction thereof.
[0045] Reference numerals 106 - 1 to 106 - 4 represent indicators that indicate the direction of the detection plane and are constructed so that they are capable of being electrically turned on/off. Also, the indicators 106 - 1 to 106 - 4 are constructed so that they perform light emission in two or more colors. To do so, for instance, these indicators each include red and blue lamps. With this construction, the indicators constitute a display portion. In this drawing, each indicator 106 is positioned outside the frame line 103 and in the vicinity of the center of one of long and short sides of the frame line 103 . Reference numeral 107 denotes a cable connecting the X-ray image taking apparatus 101 to a control apparatus (not shown), with control signals and an electronic image being communicated between the X-ray image taking apparatus 101 and the control apparatus through the cable 107 . Reference numeral 108 indicates an object, with a case where the object 108 is the right hand of a person being illustrated in the drawing as an example. In the illustrated example, an operator performs image taking by always directing the thumb side of the right hand toward the indicator 106 - 1 that performs light emission all the time. In FIG. 1 , the upper left corner of the frame line 103 is set as the coordinate original point of the two-dimensional detection plane (not shown). Also, in FIG. 1 , when the indicator 106 - 1 performs light emission in red, the downward direction of the frame line 103 becomes the positive direction of an X axis and the rightward direction thereof becomes the positive direction of a Y axis.
[0046] In contrast to this, when the indicator 106 - 1 performs light emission in blue, the long-side side indicates the positive direction of the X axis and the short-side side indicates the positive direction of the Y axis. That is, it is possible for the image taking person to recognize the coordinate original point and the coordinate system of the detection plane with reference to the light emission by the indicators. With this construction, the image taking person becomes capable of recognizing a direction in which he/she should arrange the object with respect to the X-ray image taking apparatus 101 . Hereinafter, the combination of light emission, non-light emission, and light emission color of each indicator will be referred to as the “pattern”. Also, when the gravity center position of the detection plane is set as a rotation center, the pattern is set so as to be a pattern that is not rotation-symmetric. With this construction, it becomes possible to uniquely determine the coordinate original point. Here, it is assumed that the relationship among the pattern, the coordinate original point, and the coordinate system was taught to the image taking person in advance.
[0047] FIG. 2 is an explanatory diagram where an electronic image taken with the X-ray image taking apparatus 101 is displayed on a monitor 201 (second display portion). In this drawing, reference numeral 203 denotes an object and reference numeral 202 indicates an image area. In this illustrated case, a definition has been formulated in advance so that the coordinate original point of the electronic image is positioned at the lower left corner of the display apparatus, with the positive direction of an X axis being set on the short-side side and the positive direction of a Y axis being set on the long-side side.
[0048] FIG. 3 is a schematic construction diagram of a radiation image taking system including the X-ray image taking apparatus 101 shown in FIG. 1 and the monitor 201 shown in FIG. 2 . In FIG. 3 , reference numeral 301 denotes a control portion connected to the X-ray image taking apparatus 101 , with the control portion 301 including a control means 302 , an image processing means 304 , a communication means 305 , and the like. Also, the control means 302 includes a storage means 303 for storing various settings. Reference numeral 306 indicates an operation portion (image taking direction designation portion) that performs various inputs into the control portion and also instructs displaying of information concerning operations. As information concerning the object, a part name, an image taking posture, and the like are inputted by the operation portion 306 , for instance. The control means 302 performs exchange of various control signals with the X-ray image taking apparatus 101 . Reference numeral 307 represents an X-ray generation apparatus connected to the control portion 301 and reference numeral 308 indicates an X-ray tube 308 connected to the X-ray generation apparatus 307 . With this construction, the X-ray generation apparatus 307 and the control portion 301 mutually inform of their states and exchange synchronization signals at the time of image taking. An electronic image acquired with the X-ray image taking apparatus 101 is transmitted to the image processing portion 304 which then performs desired processing on the electronic image. The electronic image subjected to the processing is sent to a network 310 in a hospital through the communication means 305 . Connected to the network 310 are an image database 311 and a workstation for image interpretation 312 . Here, it is assumed that the image processing portion 304 includes an A/D converter that A/D-converts an electrical signal from the X-ray detection sensor (X-ray detection means). Note that it is also possible to use a construction where the A/D converter is provided for the X-ray detection sensor (X-ray detection means). In this case, the image processing portion 304 becomes a portion that has only an image processing function for performing gradation conversion processing and the like.
[0049] Next, a procedure for taking a radiation image using the X-ray image taking apparatus 101 will be described with reference to a flowchart shown in FIG. 4 and the schematic construction diagram of the image taking system shown in FIG. 3 . First of all, a part to be image-taken is selected using the operation portion 306 (S 401 ). Concurrently with this part selection, information defined for the part in advance and concerning a coordinate original point, a coordinate system, image taking conditions, image processing conditions, and the like is read out from the storage means 303 and is recognized by the control means 302 (S 402 ). Here, a setting has been made so that the coordinate original point and the coordinate system of a taken electronic image coincide with the coordinate original point and the coordinate system of the monitor 201 . It is possible for the operator to make this setting in advance at desired values through input from the operation portion 306 and to store the values in the storage means 303 . Next, the operator determines the detection plane of the X-ray image taking apparatus 101 for the object (S 403 ). When doing so, the object is positioned with reference to the indicators 106 so that the object is set in the same direction at all times. Next, X rays are irradiated from the X-ray tube 308 , thereby performing image taking (S 404 ). After this image taking, an electronic image is transmitted to the image processing portion 304 which then subjects the electronic image to desired processing including image rotation and the like (S 405 ). In this example, the image processing portion 304 also has the function of a coordinate conversion portion for converting the coordinates of the image. After that, a confirmation image is displayed on the monitor 201 (S 406 ). When doing so, the aforementioned image rotation setting made for the part coincides with the direction of the object uniquely positioned with reference to the indicators 106 , so that the electronic image is displayed in a desired direction at all times. Therefore, an operation for rotating post-displaying image becomes unnecessary, which makes it possible to perform swift work. Then, it is judged whether the image taking has been ended in success using the displayed image. If it is judged that the image taking has ended in failure, image retaking is performed. On the other hand, if it is judged that the image taking has ended in success, a transmission command is inputted from the operation portion 306 (S 407 ). In response to this command, the electronic image is transmitted from the communication means 305 to the electronic image database 311 through the network 310 (S 408 ) and is stored in the electronic image database 311 (S 409 ). The stored electronic image is read out from the electronic image database 311 at the time of image interpretation or the like (S 410 ) and is displayed on a high-resolution monitor of the workstation for image interpretation 312 (S 411 ). An image interpretation doctor interprets the displayed image and prepares a diagnosis report (S 412 ). In the electronic image database 311 , the electronic image is stored under a state where it is given an image rotation parameter, so that it becomes possible for the image interpretation doctor to display the electronic image in a desired direction at the time of the displaying on the monitor.
[0050] FIGS. 5 and 6 are plan views where the object 108 is set with respect to the same X-ray image taking apparatus 101 as in FIG. 1 in different directions. In FIG. 5 , the image original point is set at the upper left corner of the frame line 103 . On the other hand, in FIG. 6 , the image original point is set at the lower left corner of the frame line 103 . That is, in these drawings, a coordinate system in the case where a certain indicator performs light emission in red is illustrated. With this construction, in each of the cases shown in FIGS. 5 and 6 , it becomes possible for the operator to recognize the coordinate original point and the coordinate system of the detection plane with ease and to correctly position the object 108 by directing the thumb side of the hand toward the indicator 106 emitting light in red like in the case shown in FIG. 1 . Therefore, even when image taking is performed under the state shown in FIG. 6 , it is possible to display the object in a desired direction as shown in FIG. 2 .
[0051] It is possible to almost uniquely determine whether the object 108 should be image-taken in the direction shown in FIG. 5 or in another direction (such as the direction shown in FIG. 6 ) in a certain image taking system, although the determined image taking direction does not necessarily become an appropriate image taking direction in another apparatus or another facility. That is, it is possible to conceive various appropriate image taking directions depending on the arrangement of apparatuses, the shape of an image taking room, the moving paths of a subject and an operator, the preference and experience of the operator, and the like. Here, it is assumed that when the cable 107 is positioned in the direction shown in FIGS. 5 and 6 , this cable 107 is positioned appropriately with respect to the arrangement of the X-ray image taking apparatus 101 and the control portion 301 shown in FIG. 3 . In this case, if an entrance, through which the subject enters into the image taking room, exists on the left side in the drawings, it is possible for the subject to move in a natural manner in the case shown in FIG. 5 . On the other hand, if the entrance exists on the right side in the drawings, it is possible for the subject to move in a natural manner in the case shown in FIG. 6 . Accordingly, an effect is also produced that by changing the coordinate original point and the coordinate system as appropriate, it is possible to perform the image taking with more ease.
[0052] In addition, an effect is provided that even when printing is performed by making an annotation in the upper portion or the like of an electronic image, it is possible to maintain a desired positional relationship between the object and the annotation.
[0053] Next, a second embodiment of the present invention will be described. Here, the same reference numerals as in FIG. 1 denote the same members.
[0054] FIGS. 7 and 8 are each an enlarged view of an indicator portion of the second embodiment of the present invention. Each not-illustrated portion other than the indicator portion is the same as that in the first embodiment. That is, only the indicator portion 106 in the first embodiment is modified in this second embodiment. In FIGS. 7 and 8 , reference numeral 701 denotes a sliding indicator portion that has a mechanism with which the indicator portion is capable of moving in a right-left direction in the drawings with respect to an opening portion 703 of an enclosure plane. When a protrusion 701 c of the indicator portion 701 exists at a position shown in FIG. 7 , a surface 701 a , on which an indicator 702 is illustrated, is exposed to the outside through the opening portion 703 . On the other hand, when the protrusion 701 c is pushed and is moved in the rightward direction from the position shown in FIG. 7 , a state shown in FIG. 8 is obtained in which a surface 701 b , on which no indicator is illustrated, is exposed to the outside through the opening portion 703 . The sliding portion 701 has a mechanism with which it is fixable at the positions shown in FIGS. 7 and 8 . Then, when the protrusion 701 c is pushed in the horizontal direction with a certain force, the sliding portion 701 set at one of the positions shown in FIGS. 7 and 8 is moved and is set at the other of the positions. By providing such indicator portions at multiple locations of the enclosure plane, it becomes possible for the operator to arrange the indicators at desired positions. Also, it is possible for the operator to change the display positions of the indicators with ease. These sliding indicator portions are driven by a motor (not shown) and the motor receives control by the control portion 302 . It is also possible to express a coordinate system by providing two kinds of indicators 702 that are in red and blue along one long side.
[0055] It should be noted here that in the above description, the sliding portion 701 is motor-driven, although it is also possible to use a construction where the sliding portion 701 is slid manually. In this case, the control by the control portion 302 becomes unnecessary.
[0056] FIGS. 9 and 10 each show a third embodiment of the present invention that differs from the first embodiment in that the indicators 106 shown in FIG. 1 are changed to an indicator 901 that is movable to an arbitrary position and is fixable at the position after the movement.
[0057] Various forms are conceivable as a mechanism for moving and fixing the indicator. In the case shown in FIGS. 9 and 10 , the triangular indicator 901 is produced as a sticker having an adhesive on its undersurface. With this construction, it becomes possible for the operator to stick the indicator 901 at his/her preferred position. In this case, the control by the control portion 302 becomes unnecessary.
[0058] FIG. 11 is a plan view showing a fourth embodiment of the present invention. In this embodiment, 16 indicators 1102 that are each capable of being electrically turned on/off are arranged for an X-ray image taking apparatus 1101 . Here, each indicator 1102 is controlled by a control portion (not shown) and is set under one of three states: a state where it is turned on to emit light in red (indicators 1102 b and 1102 e in FIG. 11 ); a state where it is turned on to emit light in green (indicators 1102 a , 1102 c , 1102 d , and 1102 f in FIG. 11 ); and a state where it is turned off (all of the remaining indicators 1102 in FIG. 11 ). Each indicator turned on in red indicates the direction of the object and also represents the center lines of the object. On the other hand, each indicator turned on in green indicates the approximate range of the object and it is possible for an operator to adjust the irradiation range of X rays with reference to this range. With this construction, in addition to the same effect as in the first embodiment, an effect is provided that it is possible to provide the operator with more detailed information.
[0059] FIG. 12 is a plan view showing a fifth embodiment of the present invention. In this embodiment, a display portion 1202 (second display means), such as a liquid crystal display apparatus, that displays a two-dimensional image is provided for an X-ray image taking apparatus 1201 . The display portion 1202 is capable of displaying a two-dimensional image expressing the schematic shape or the like of an object. When a part to be image-taken is selected, a schematic shape 1203 of the part is displayed on the display portion 1202 (second display means). The direction of the schematic shape 1203 coincides with a direction that is appropriate at the time of displaying after image taking. With this construction, an operation for storing the positional relationship between an indicator and an object (such as the alignment of a right hand thumb with an indicator) becomes unnecessary, which makes it possible to position the object more intuitively. As a result, work efficiency is further improved.
[0060] Next, an example where the display position of the indicator in the third embodiment is changed will be described. The same reference numerals as in FIG. 1 denote the same members.
[0061] FIG. 13 shows a sixth embodiment where an indicator 1302 is arranged along one of the long sides of a frame line 103 of an enclosure plane of an X-ray image taking apparatus 1301 . The indicator 1302 has a length that is approximately equal to the total length of the long side of the frame line 103 .
[0062] FIG. 14 shows a seventh embodiment where like in the third embodiment, an indicator 1402 is arranged outside a frame line 103 of an enclosure plane of an X-ray image taking apparatus 1401 and in the vicinity of the center of one of the long sides of the frame line 103 . In this seventh embodiment, however, an indicator 1403 is also provided outside the frame line 103 and in the vicinity of the center of one of the short sides of the frame line 103 .
[0063] FIG. 15 shows an eighth embodiment where like in the sixth embodiment, an indicator 1502 is arranged along one of the long sides of a frame line 103 of an enclosure plane of an X-ray image taking apparatus 1501 . In this eighth embodiment, however, an indicator 1503 is also arranged along one of the short sides of the frame line 103 .
[0064] FIG. 16 shows a ninth embodiment where indicators 1602 and 1603 are arranged outside a frame line 103 of an enclosure plane of an X-ray image taking apparatus 1601 , with the indicator 1602 having a length that is around ½ of the length of the long sides of the frame line 103 and the indicator 1603 having a length that is around ½ of the length of the short sides of the frame line 103 . The indicator 1602 is arranged outside the frame line 103 and between the center of one of the long sides of the frame line and a certain corner and the indicator 1603 is arranged outside the frame line 103 and between the center of one of the short sides of the frame line and the certain corner.
[0065] FIG. 17 shows a tenth embodiment where an indicator 1702 is arranged in the vicinity of a corner of a frame line 103 of an enclosure plane of an X-ray image taking apparatus 1701 . In this drawing, reference numeral 1703 denotes an object and a case where the right arm of a person is positioned along a diagonal line of the frame line 103 is illustrated as an example.
[0066] FIG. 18 shows an eleventh embodiment where the color tint in a region 1802 divided by center lines 104 and 105 of an enclosure plane of an X-ray image taking apparatus 1801 is set so as to be different from those in other regions. That is, in this embodiment, the region 1802 is displayed so as to be distinguished from the other regions.
[0067] FIG. 19 shows a twelfth embodiment where the color tint in a region 1902 in the vicinity of the intersection of center lines 104 and 105 of an enclosure plane of an X-ray image taking apparatus 1901 is set so as to be different from those in other regions, thereby setting the region 1902 as an indicator.
[0068] FIG. 20 shows a thirteenth embodiment where a center line extending between the long sides of an enclosure plane of an X-ray image taking apparatus 2001 and a center line extending between the short sides of the enclosure plane are divided at their centers and solid line portions 2002 and 2004 and dotted line portions 2003 and 2005 are displayed so as to be distinguished from each other.
[0069] FIG. 21 shows a fourteenth embodiment where instead of the frame line 103 , indicators 2102 , 2103 , 2104 , and 2105 indicating a range in a short-side direction of a rectangular detection area and indicators 2106 , 2107 , 2108 , and 2109 indicating a range in a long-side direction thereof are arranged for an enclosure plane of an X-ray image taking apparatus 2101 . Also, indicators 2110 and 2111 indicating the center in the short-side direction and indicators 2112 and 2113 indicating the center in the long-side direction are provided. Further, the opposing indicators 2110 and 2111 are set so as to have different color tints and the opposing indicators 2112 and 2113 are set so as to have different color tints. In this manner, the indicators 2110 to 2113 are set as indicators of rotation within a detection plane.
[0070] The present invention is not limited to the embodiments described above and various modifications are conceivable.
[0071] For instance, in each embodiment described above, a case where the enclosure of the X-ray image-taking apparatus is provided with a communication cable and a grip has been described as an example, although it is not necessarily required to provide the communication cable and the grip for the enclosure. Also, the enclosure may have a shape that is rotation-symmetric within the detection plane. Further, the detection plane of the X-ray detection means is not limited to the rectangular shape.
[0072] As described above, with the X-ray image taking apparatus according to the present invention that is a transportable apparatus, flexibility in alignment at the time of image taking is increased by making it possible to maintain an appropriate relative positional relationship between the original point of an electronic image and an object at all times with reference to the indicators. Therefore, it becomes possible to display an image of the same part in the same desired direction at all times. As a result, it becomes possible to eliminate the necessity to perform image rotation work to an appropriate direction each time image confirmation is performed at the time of image taking or each time an image interpretation is made, which makes it possible to increase work efficiency.
[0073] When each indicator for discrimination of a rotation direction is arranged in the vicinity of its corresponding center line of a detection plane, it also becomes easy to arrange an object in the center portion of the detection plane.
[0074] When each indicator for discrimination of a rotation direction has a length that is approximately equal to the length of its corresponding side of the outer frame of a detection plane, there rarely occurs a situation where the indicator is hidden behind an object, which facilitates confirmation.
[0075] When each indicator for discrimination of a rotation direction exists in the vicinity of two sides of an outer frame or in the vicinity of one corner thereof, in particular when positioning is performed along a diagonal line of the rectangular shape of a detection plane, it becomes easy to recognize a specific corner of the detection plane.
[0076] It should be noted here that it is possible to realize the control means and the image processing means described in the first to fourteenth embodiments with a computer. Therefore, it is to be understood that an object of the present invention may also be accomplished by supplying a system or an apparatus with a storage medium storing a program code of software that realizes the functions of the above-mentioned embodiments and causing a computer (or a CPU or an MPU) of the system or the apparatus to read out and execute the program code stored in the storage medium.
[0077] In this case, the program code itself read out from the storage medium realizes the functions of the above-mentioned embodiments, which means that the storage medium storing the program code also constitutes the present invention.
[0078] Examples of the storage medium for supplying the program code include a flexible disk, a hard disk, an optical disk, a magneto-optical disk, a CD-ROM, a CD-R, a magnetic tape, a nonvolatile memory card, a ROM, and the like.
[0079] Also, it is needless to mention that, the functions of the above-mentioned embodiments may be accomplished not only by executing the program code read out by the computer but also by causing an operating system (OS) or the like running on the computer to perform a part or all of actual processing based on instructions of the program code.
[0080] Further, needless to say, the functions of the above-mentioned embodiments may be accomplished by writing the program code read out from the storage medium into a memory provided on a function expansion board inserted into the computer or a function expansion unit connected to the computer and then causing a CPU or the like provided on the function expansion board or the function expansion unit to perform a part or all of the actual processing based on instructions of the program code.
[0081] With the construction described above according to the present invention, the X-ray image taking apparatus according to the present invention provides an effect that it is possible for an image taking person to recognize the positional relationship between the X-ray image taking apparatus and an object with ease.
[0082] This application claims priority from Japanese Patent Application No. 2003-209517 filed on Aug. 29, 2003, which is hereby incorporated by reference herein.
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The present invention relates to a radiation image taking apparatus including: a radiation image acquisition portion that acquires an electronic image based on a radiation transmitted through an object and outputs the electronic image; an image taking direction designation portion that designates a posture of the object with respect to the radiation image acquisition portion; a display portion that displays the posture of the object on at least one plane of the radiation image acquisition portion; and a coordinate conversion portion that performs coordinate conversion of the electronic image. The radiation image taking apparatus further includes a control portion that controls the displaying of the posture by the display portion and the coordinate conversion by the coordinate conversion portion based on the posture designated by the image taking direction designation portion.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to semiconductor processing, particularly to etching of dielectric materials in semiconductor devices, and more particularly to pre-emitter and pre-base etching of silicon dioxide therein.
[0003] 2. Description of Related Art
[0004] U.S. Pat. No. 5,282,925 of Jeng et al. “Device and Method for Accurate Etching and Removal of Thin Film” (commonly assigned) describes a device and a method known as Chemical Oxide Removal (COR) for accurate etching and removal of a thin layer by controlling the surface residence time, thickness and composition of reactant containing film. The COR process employs etching with gaseous reactants comprising HF and NH 3. As the gaseous reactants contact the silicon oxide surface, a film of reaction products is formed on the silicon oxide by adsorption or condensation of the reactant gases on the silicon oxide surface at a pressure near the vapor pressure. Generally, the process of Jeng et al. etches silicon oxide from a wafer by admitting reactant vapor to a chamber which forms a film on a wafer. Etching is adjusted by controlling the film as well as chamber temperature. After etching is completed, the resulting residue can be removed by thermal desorption.
[0005] U.S. Pat. No. 5,980,770 of Ramachandran et al. for “Removal of Post-RIE Polymer on Al/Cu Metal Line” (commonly assigned) describes a COR application which removes RIE sidewall films from an aluminum line employing an etching agent comprising a gaseous or plasma mixture of HF as an etching gas and NH 3 as an acid neutralizing gas to remove post-RIE polymer rails on an Al/Cu metal line by chemically modifying the polymer rails into a water soluble form. It is best reacted with COR in the RIE cluster before removal into the atmosphere so that the RIE sidewall does not cause corrosion of the aluminum line. The tool cluster is a conventional RIE cluster with a unique combination of process modules.
[0006] U.S. Pat. No. 6,335,261 of Natzle, et al. for “Directional CVD Process with Optimized Etchback” describes a COR process producing a solid reaction product “believed to be ammonium hexafluorosilicate ((NH 4 ) 2 SiF 6 )” which has a specific volume approximately three times that of the original silicon dioxide producing a reaction at an overhang that causes a gap to be closed, so that after the gap is closed no further etching of an oxide underlying that closed gap occurs. However, etching continues at the oxide layer on the upper surface of the substrate. The solid product slows the reaction by impeding diffusion of the NH 3 /HF reactants through the product to the underlying oxide, and as a result the etching process reaches a self-limiting point where the solid reaction product becomes too thick to permit further etching of the underlying oxide.
[0007] U.S. Pat. No. 6,194,286 B1 of Torek for “Method of Etching Thermally Grown Oxide Substantially Selectively Relative to Deposited Oxide” describes processing deposited silicon oxide (e.g. silicon oxide formed by PECVD) and outwardly exposed grown silicon oxide materials (which may be thermally grown). The outwardly exposed silicon dioxide layer is vapor etched substantially selectively to the deposited silicon dioxide layer using an etch chemistry comprising a substantially anhydrous HF (no greater than 10% water by volume) and an organic primer (e.g alcohols and ketones).
[0008] U.S. Pat. No. 5,223,443 of Chinn et al. for “Method for Determining Wafer Cleanliness” describes a method for determining the cleanliness of a semiconductor wafer comprising the steps of depositing a thin tetraethylorthosilicate (TEOS) glass film over the entire surface of a wafer and then exposing the wafer to a solution of KOH that attacks the polysilicon, but which is selective to and does not etch the TEOS glass film for the purpose of exposing pin holes during visual inspection.
[0009] In the past, integrated tools which include multi-processing, multichamber systems which transport single wafers between a series of interconnected process chambers have been provided as exemplified by U.S. Pat. Nos. 5,076,205; 4,917,556; 5,024,570; and Japanese JP1 0036970A which are discussed below.
[0010] U.S. Pat. No. 5,076,205 of Vowles et al. for “Modular Vapor Process System” shows a multichamber, multi-processing, system in which individual processing chambers are mobile to permit exchange thereof readily without requiring complete evacuation of the system. The processing capability of the system is extended by using a wafer buffer storage cassette/elevator system. The system is expanded to include a number of processing chambers permitting wafer input and output access at intermediate points.
[0011] U.S. Pat. No. 4,917,556 of Stark et al. for “Modular Wafer Transport and Processing System” describes a wafer processing machine including multiple loadlocks for loading whole cassettes into the vacuum environment. However, the wafers are transported individually. Wafer handling modules containing robot arms from a spine of the machine through which wafers are passed. Various processing modules are attached to the sides of the wafer handling modules.
[0012] U.S. Pat. No. 5,024,570 of Kiriseko et al. for “Continuous Semiconductor Substrate Processing System” describes a wafer processing system which includes a stocker coupled to the conveying mechanism to hold semiconductor wafers temporarily during the processing, but it does not transport the wafers in a vacuum. It also includes a wafer storage section for storing semiconductor wafers; a transfer mechanism for transferring semiconductor wafers between storage section and conveying mechanism; a wafer discrimination section for discriminating the semiconductor wafers; and a carrier feed-in-feed-out section capable of feeding in and feeding out semiconductor wafers.
[0013] JP10036970A of Kiyoshi for “Thin Film Vapor Growth Apparatus” provides a transfer chamber for carrying a wafer from an adjacent vacuum chamber onto a reactor (growth chamber) for growing a thin film on the wafer in the vacuum chamber. The apparatus provides for linear transport of a single wafer without even unchucking the wafer.
[0014] A number of defects are associated with stripping of silicon oxide from the surface of a workpiece such as a doped silicon semiconductor substrate with an aqueous HF solution, prior to deposition of base and emitter regions in bipolar devices, in BiCMOS integration schemes and in strained CMOS devices (for example, devices described in commonly assigned U.S. Pat. No. 6,429,061 of Rim for “Method to Fabricate a Strained Si CMOS Structure Using Selective Epitaxial Deposition of Si after Device Isolation Formation.” Such defects may be caused directly by damage from exposure to the aqueous solution or indirectly by the effects from the inherent delay resulting from the changes which occur in the exposed surface of the workpiece. For example, the surface may be exposed to harmful gases in an ambient atmosphere during the time between aqueous HF treatment and a subsequent vacuum deposition process.
[0015] It is well known that an aqueous HF solution can leave a partially passivated surface on a silicon, semiconductor substrate, thus enabling a non-integrated oxide strip, but the remaining delay is a manufacturing problem, especially for the case of etching before forming the base of a transistor, i.e. a “pre-base etch”. Since aqueous etches are generally batch processes, the delay is particularly severe when deposition involves a subsequent single wafer process, or if a single wafer strip precedes a batch deposition. Such a wet single wafer strip is described in U.S. Pat. No. 6,162,739 of Sumnitsch et al. assigned to SEZ Semiconductor-Equipment Zubehor fur die Halbleiterfertigung AG for a “Process for wet etching of semiconductor wafers.” The process of Sumnitsch et al. '739 includes entirely removing a silicon dioxide layer from a top side and selectively removing the silicon dioxide layer from the opposite side in a defined area which extends to the inside from the peripheral edge of the semiconductor wafer, using an etching medium which includes hydrofluoric acid or a combination of hydrofluoric acid and ammonium fluoride and at least one carboxylic acid.
[0016] If a single wafer strip such as described in the '739 patent precedes a batch deposition, the delay is lengthened by the processing mismatch between a batch and single wafer operation.
[0017] A summary of some problems associated with conventional aqueous etch processing is as follows:
[0018] (A) Exposed silicon oxide located spaced away from the base or emitter regions is attacked, creating shorts between the emitter and the base or producing detrimental topography in Shallow Trench Isolation (STI) and elsewhere, so that it is difficult to provide later silicidation of overlying silicon.
[0019] (B) Isolation features between the base and the emitter can be undercut.
[0020] (C) Defects and crevices in exposed silicon, which later becomes the polysilicon gate for an accompanying CMOS device, can be penetrated by the aqueous etching solution, thereby attacking the underlying gate oxide layer.
[0021] (D) Residual silicon oxide from regrowth at the base/collector interface can produce defects during base epitaxy leading to leakage between emitter and collector; residual silicon oxide from regrowth at the base/emitter interface can contribute to higher resistance between the base and the emitter. If partial silicon oxide regrowth is followed by additional wet cleans able to remove the silicon oxide, then silicon reacted during oxide regrowth will be consumed, contributing to defects.
[0022] Further details regarding these problems are given below.
[0023] (A) Attack of Exposed Silicon Oxides (Example: Emitter Pre-Etch)
[0024] During fabrication of the new generation of SiGe BiCMOS, a critical step involves the achievement of isolation between the emitter polysilicon and the extrinsic polysilicon by means of insulators such as TetraEthylOrthoSilicate (TEOS) silicon oxide, hereinafter referred to as TEOS. The starting thickness of the TEOS is within a certain range between about 500 Å and about 1000 Å, as defined by the previous CMP processes.
[0025] There is also a stringent thermal requirement after deposition of the base, namely that in order to avoid severe dopant diffusion, any high temperature annealing for the purpose of hardening the TEOS is strictly prohibited.
[0026] Before the deposition of the emitter polysilicon, it is required that the thin HIPOX protection film (about 100 Å) on top of the base layer must be removed. There are several problems associated with the exposure of the isolation TEOS and the protection of the HIPOX (High Pressure OXide) layer at the same time during the removal of the HIPOX layer.
[0027] A HIPOX layer is kind of silicon oxide layer which is the product of a high pressure oxidation process. The HIPOX process can employ high pressure steam, high pressure oxygen, or a combination thereof to produce a silicon oxide layer. See U.S. Pat. No. 5,128,271 of Bronner et al., which indicates that the essential process sequence of the HIPOX process is described in “Low Temperature, High Pressure Steam Oxidation of Silicon,” by L. E. Katz and B. F. Howells, Jr. in J. Electrochem. Soc., Vol. 126, p. 1822 (1979), which is hereby incorporated by reference. In an exemplary HIPOX process, the base is formed on a bare N-epi/N+ subcollector/P-substrate with an annealed reach-through implant. A 100 Å etch stop oxide (ESOX) is grown by HIPOX (e.g., in 10 atmospheres of steam at 700° C.), followed by formation of a P+ in-situ doped polysilicon extrinsic base and a TEOS layer. A hole is etched to the ESOX; a sidewall is then formed on the ESOX. The ESOX is then stripped with aqueous HF, and emitter polysilicon is deposited, doped and patterned. Emitter anneal (e.g., 850° C. for 20 min.), contact, and metallization steps are then performed.
[0028] Two consequences of the conventional HIPOX process are as follows:
[0029] (1) The TEOS layer covering the extrinsic polysilicon base will be completely removed, when the thin HIPOX layer for the base protection is stripped by HF during the process of forming the emitter opening. This is due to the much higher etch rate of the TEOS compared to the silicon oxide; wet HF etch removes TEOS about 10 times faster than the HIPOX.
[0030] (2) Even with a HIPOX oxidation of the extrinsic polysilicon to achieve a soft etch stop for the DHF wet strip, the thick TEOS will be mostly removed causing not only potential leakage in case there are defects in the HIPOX, but also severe increase in the parasitic capacitance. So, from the device performance point of view, maintaining a thick TEOS is highly desirable.
[0031] Furthermore, as noted above, undesirable topography is produced on STI (Shallow Trench Isolation) which results in part from the aqueous HF etch associated with a pre-base strip.
[0032] (B) Undercutting of Emitter/Base Sidewall Isolation
[0033] [0033]FIGS. 1A and 1B illustrate the problem of undercutting of emitter/base sidewall isolation nitride in a bipolar device BP. FIG. 1A shows bipolar device BP formed of a silicon substrate SI covered with a HIPOX layer HX, upon which a polysilicon layer PS and a TEOS layer TS are formed with a window W therethrough exposing the central portion of the HIPOX layer HX. Silicon nitride sidewall spacers SW have been formed on the sidewalls of the layers PS and TS. An aqueous solution of HF undercuts HIPOX layers in a HIPOX strip which can cause problems with the bipolar portion of a device.
[0034] [0034]FIG. 1B shows the device BP of FIG. 1A after an aqueous solution of HF has been used to strip the HIPOX layer HX at the base of the window W. One problem is that the TEOS has been etched away, i.e. completely removed as an unwanted side effect of removing the exposed portions of the HIPOX layer HX. Furthermore, an undercut UC has been formed below the sidewall spacers SW and possibly, as shown, extending under the polysilicon layer PS which is now cantilevered. The undercut UC is very problematic for process control often resulting in defect, leakage, or unwanted topography.
[0035] There is a need for an etching process which does not have the adverse side effect of undercutting below the sidewall nitride, i.e. which limits undercutting of the HIPOX layer and the like.
[0036] (C) Penetration of Defects in Polysilicon Gate Layer of CMOS Devices
[0037] HF penetrates polysilicon during a HIPOX strip which can cause problems with the CMOS portion of a device. FIGS. 2A and 2B illustrate the problem for a CMOS device CM which comprises a silicon substrate SI on which a blanket gate oxide layer GX, has been formed, covered by a blanket layer of gate electrode polysilicon GP. In FIG. 2A a CMOS device CM is shown with a polysilicon defect PD in the polysilicon layer GP. FIG. 2B shows the device CM of FIG. 2A after treatment with an aqueous solution of HF which has penetrated through the defect in the gate polysilicon layer GP to create an oxide defect OD in the gate oxide GX.
[0038] Thus an etching process which does not have the adverse side effect of penetrating thin fissures in polysilicon layers and the like is needed.
[0039] (D) Residual Silicon Oxide
[0040] Regrowth of silicon oxide at the collector/emitter interface following a process of stripping in an aqueous HF solution causes yield loss. The manufacturing process window for atmospheric exposure is as small as 15 minutes between a silicon oxide stripping process and the growth of base epitaxy. Accordingly, there is a need for a silicon oxide etching process which can be integrated into a single tool which can also perform a process for epitaxial growth of a silicon containing layer or polycrystalline growth of a silicon layer.
[0041] FIGS. 3 A- 3 E illustrate other aspects of the problem of using a wet chemical etch on a bipolar structure.
[0042] [0042]FIG. 3A shows a device 10 in an early stage of manufacture. A silicon substrate 12 includes at the bottom a region comprising doped silicon collector 14 . A doped silicon base 16 which comprises the intrinsic base region is formed above the silicon collector 14 . A thin HIgh Pressure Oxide (HIPOX) layer 18 is formed on the surface of the substrate 12 above the intrinsic base 16 . A blanket extrinsic base polysilicon layer 20 (Poly 1 ) is formed on top of the HIPOX layer 18 . A blanket glass film in the form of a TetraEthylOrthoSilicate (TEOS) silicon dioxide layer 22 is formed on the surface of the Polyl layer 20 . The Polyl layer 20 which is the extrinsic base is electrically connected to the intrinsic base 16 in another region (not shown) and the TEOS layer 22 is provided as electrical insulation between the Polyl layer 20 and the emitter which is to be added, as shown in FIG. 3E.
[0043] [0043]FIG. 3B shows the device 10 of FIG. 3A after formation of a window 24 through TEOS layer 22 and polysilicon layer 20 down to the top surface of the HIPOX layer 18 by photolithography and etching, as will be well understood by those skilled in the art.
[0044] [0044]FIG. 3C shows the device 10 of FIG. 3B after formation of silicon nitride (SiN) spacers 26 from the exposed surface of the HIPOX layer 18 reaching up along the sidewalls of the TEOS layer 22 and the polysilicon layer 20 in the window 24 .
[0045] [0045]FIG. 3D shows the device 10 of FIG. 3C after wet etching with an aqueous solution of HF. In this case, the TEOS layer 22 has been etched away, i.e. completely removed, and the HIPOX layer 18 has been partially etched away below the spacers 26 , leaving them less cantilevered than in FIG. 1B, but nevertheless, even this degree of undercut is unacceptable. The removal of the TEOS layer 22 is also undesirable as can be seen with reference to FIG. 3E.
[0046] [0046]FIG. 3E shows the device 10 of FIG. 3D after an emitter 30 has been formed filling the window 24 , covering the spikes of the sidewall spacers 26 which were exposed by the unwanted removal of the TEOS layer 22 and reaching down to short circuit the emitter 30 to the exposed surface of the Polyl layer 20 .
[0047] There is a need for an oxide etch process which avoids unwanted attack of exposed silicon oxides, limits undercutting of sidewall isolation, and will not further damage a defective polysilicon layer. Furthermore, there is a need for an oxide etch process which can be integrated with a Si or Si/Ge growth process, so that the wafer need not be exposed to the atmosphere after the etch process.
SUMMARY OF THE INVENTION
[0048] An object of this invention is to provide an improved silicon oxide etching process for the manufacture of semiconductor devices formed of silicon oxides including HIPOX and gate oxides formed on a substrate upon which a polysilicon layer has been formed.
[0049] It is also an object of this invention is to integrate a silicon oxide etching process chamber into a tooling system which includes a chamber for subsequent silicon deposition.
[0050] In accordance with this invention a process is provided employing etching of silicon dioxide in a vacuum chamber by COR, e.g. using a mixture of HF and ammonia NH 3 vapor; thermal silicon oxide and silicon oxide deposited using TEOS; TEOS silicon oxide as an isolation layer in bipolar and CMOS device fabrication; and a tool with handler able to move wafers from HF and ammonia reaction, to product evaporation, to Si or Si/Ge deposition without breaking the vacuum.
[0051] A batch system is employed wherein a cassette of a plurality of wafers is moved simultaneously from a precleaning chamber to a furnace deposition chamber. SiGe layers are deposited at a low rate with a batch furnace at Ultra High Vacuum (UHV) pressures. The step of precleaning is performed in a batch precleaning chamber which is coupled to a batch furnace without the inefficiency of handling each wafer individually. This sort of tooling has not been disclosed previously, because no precleaning chamber was available which could process a batch of wafers at low enough pressures to couple to an Ultra High Vacuum (UHV) furnace.
[0052] In accordance with this invention, a device and a method are described for accurate etching and removal of thin layer by controlling the surface residence time, thickness and composition of the reactant containing film. The invention is applicable to etching using a condensed or adsorbed reactant film of HF and NH 3 , as discussed below. An embodiment of this invention includes the following steps:
[0053] (a) forming a silicon substrate with a silicon oxide layer which further includes a structure which is damageable by an aqueous HF etch followed by atmospheric exposure;
[0054] (b) reacting the silicon oxide layer with the HF vapor and ammonia vapor to form a reaction product;
[0055] (c) removing the reaction product to expose the silicon substrate;
[0056] (d) forming a layer comprising silicon on the exposed region of the silicon substrate; and
[0057] (e) further processing the substrate wherein the silicon layer is made part of a transistor or bipolar transistor.
[0058] Steps (b), (c) and (d) can be performed within a single closed COR system, e.g. a vacuum system. The damageable structure provided in step (a) can be the silicon substrate itself, a layer of silicon oxide which provides electrical isolation between transistor elements, a layer of silicon oxide underlying a masking layer such as a nitride sidewall, or a polysilicon layer which overlies a silicon oxide which, through further processing, is to become the gate dielectric of a CMOS transistor. The region of silicon substrate exposed in step (c) can be a collector or a base in a bipolar transistor. The layer comprising silicon in step (d) can be silicon or silicon/germanium.
[0059] It should be noted that commonly assigned U.S. Pat. No. 5,282,925 of Jeng et al. describes a Chemical Oxide Removal (COR) reaction, but does not describe the application of COR as a preclean for construction of SiGe bipolar transistors, the configuration of HIPOX glass to be etched while preserving TEOS glass, or describe tooling for coupling of a batch COR reaction chamber to a batch SiGe furnace which is the best tooling implementation for this application.
[0060] In addition, the tooling of the present invention may be distinguished from that described in Ramachandran et al. in that the present invention provides a combination of modules and tool structures which may be used for any sequential combination of batch processes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] The foregoing and other aspects and advantages of this invention are explained and described below with reference to the accompanying drawings, in which:
[0062] [0062]FIGS. 1A and 1B illustrate the problem of undercutting of emitter/base sidewall isolation nitride in a bipolar device.
[0063] [0063]FIGS. 2A and 2B illustrate the problem of defects and crevices in an exposed gate electrode polysilicon layer of a CMOS device which can be penetrated by an aqueous etching solution thereby attacking an underlying gate oxide layer.
[0064] FIGS. 3 A- 3 E illustrate other aspects of the problem of using a wet chemical etch on a bipolar structure.
[0065] FIGS. 4 A- 4 I illustrate a process of vapor phase etching (i.e. using a dry etching process) in accordance with an embodiment of this invention, when manufacturing the type of bipolar structure discussed above in connection with FIGS. 3 A- 3 E.
[0066] [0066]FIG. 5. shows a tool in accordance with this invention with a handler able to move wafers from the HF and ammonia reaction, to product evaporation, to Si or Si/Ge deposition without breaking vacuum.
[0067] FIGS. 6 A- 6 C show another tool in accordance with this invention with a handler able to move wafers from the HF and ammonia reaction, to product evaporation, to Si or Si/Ge deposition without breaking vacuum.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0068] Vapor Phase Etching Process
[0069] (I) Process Sequence
[0070] FIGS. 4 A- 4 I illustrate a process of vapor phase etching (i.e. using a dry etching process) in accordance with an embodiment of this invention, when manufacturing the type of bipolar structure discussed above in connection with FIGS. 3 A- 3 E. This process overcomes the problems of complete removal of the TEOS layer 22 and undercutting of the HIPOX layer 18 .
[0071] The structure formed in FIGS. 4 A- 4 C is identical to FIGS. 3 A- 3 C, with the same steps performed as described above, and with repeated reference numbers referring to identical elements.
[0072] [0072]FIG. 4D illustrates the result after commencing a step of precleaning of device 10 of FIG. 1A. The precleaning starts with introduction thereof into a sealed COR reaction chamber 44 in which a Chemical Oxide Removal (COR) process uses gas phase reactants to perform a self-limiting etch that is adjustable by controlling the parameters in the COR reaction chamber 44 . The COR etching process employed in the present invention comprises a vapor phase chemical oxide removal process in which a combination of the vapors of HF and NH 3 are employed as the etchant and carried out under low pressures (10 millitorr or below).
[0073] A first reservoir (not shown for convenience of illustration) connected to line 47 is filled with a first reactant comprising HF vapor, and a second reservoir (not shown for convenience of illustration) connected to line 51 is filled with a second reactant comprising NH 3 vapor. Valve 48 connects from line 47 through line 49 to an open inlet to the COR reaction chamber 44 for admission of HF vapor into chamber 44 . Similarly, the valve 52 connects from line 51 through line 53 to an open inlet to the COR reaction chamber 44 for admission of NH 3 vapor therein. Exhaust line 54 connects through exhaust valve 56 to line 58 to the exhaust pump 60 which pumps exhaust gases to outlet line 62 for removal of gases from the COR reaction chamber 44 . As shown in commonly assigned U.S. Pat. No. 5,282,925 of Jeng, Natzle and Yu for “Device and Method for Accurate Etching and Removal of Thin Film,” a microbalance and a mount may be employed in the process, and the description thereof is incorporated herein by reference since those elements are not shown for convenience of illustration.
[0074] In the preferred mode of operation, the exhaust valve 56 to the vacuum pump 60 is open during admission of the first and second reactant gases into the sealed COR reaction chamber 44 after opening of valves 48 and 52 . In operation, a COR adsorbed reactant film 27 is caused to deposit upon the surface of the device 10 when the valves 48 and 52 are opened. Preferably valves 48 and 52 are opened rapidly. The first and second reactants fill the COR reaction chamber 44 rapidly, and preferably the two reactants rapidly form the COR adsorbed reactant film 27 which remains on the exposed surface of the device 10 for a short period of time when the pressure of NH 3 and HF is above the vapor pressure at the temperature of the device 10 . The blanket COR adsorbed reactant film 27 is thus formed on the exposed surfaces of the device 10 , and the reaction with the exposed surface of the HIPOX layer 18 to be etched at the bottom of the window 24 is initiated.
[0075] In FIG. 4D, for purposes of illustration, the adsorbed reactant film 27 is shown, with considerable thickness. However, in fact, an amount of a few monolayers to less than a full monolayer is preferred. In addition, FIG. 4D shows the device 10 at the initiation of the reaction involved in the COR etching process.
[0076] [0076]FIG. 4E shows the device of FIG. 4D after a reaction product 28 comprising ammonium hexafluorosilicate ((NH 4 ) 2 SiF 6 ) has formed beneath the adsorbed reactant film 27 . Eventually the reaction product 28 will replace the adsorbed reactant film 27 everywhere, in a subsequent phase of the COR process of this invention as illustrated by FIG. 4F. The reaction product 28 has replaced only a portion of the TEOS layer 22 , but it has replaced all of the HIPOX layer 18 immediately below the window W. At the completion of the reaction, reactant inlet valves 48 and 52 are closed eliminating the supply of reactant gases from inlet lines 49 and 53 .
[0077] Since the exhaust valve 56 remains open, the adsorbed reactant film 27 eventually disappears as HF and NH 3 vapors are pumped out of COR reaction chamber 44 , as illustrated by FIG. 4F.
[0078] Completion of the reaction and the amount of the TEOS layer 22 and the HIPOX layer 18 which are removed is a function of the substrate temperature, composition and residence time of the adsorbed reactant film 27 . Factors that influence the amount removed per unit time includes vapor pressure of the reactant at the temperature of the substrate 12 , the amount of reactant or the rate of reactant admitted to the sealed COR reaction chamber 44 , the pumping speed of pump 60 , and the reaction rate between the adsorbed reactant film 27 and the HIPOX layer 18 to be etched, all of which can be regulated by a controller as indicated in the Jeng et al. patent. We have discovered that the rate of etching in the COR reaction chamber 44 of the HIPOX layer 18 is far greater than the rate of etching of the TEOS layer 22 . We believe that there is chemical and/or structural difference between the TEOS and HIPOX materials which causes the marked selectivity of the COR process to removal of HIPOX while leaving TEOS relatively intact. We have also discovered that thermal oxides including both high temperature and low temperature thermal oxides (such as HIPOX) are etched more rapidly by the COR process than the TEOS oxides which are formed by chemical decomposition which produces a material with different characteristics.
[0079] The HF and NH 3 reaction with the silicon dioxide of the HIPOX layer 18 is a multiple step process.
[0080] First, as illustrated in FIG. 4F, the adsorbed reactant film 27 from the HF and NH 3 gases has reacted with the HIPOX layer 18 and the portions of the surface of the TEOS layer 22 in contact therewith to form a condensed, solid COR reaction product 28 thereon beneath the adsorbed reactant film 27 from the reaction between the HF and NH 3 gases and the HIPOX layer 18 and the portions of the surface of the TEOS layer 22 in contact therewith as long as a sufficient vapor pressure of the reactant gases (HF and NH 3 ) remains in the chamber 44 . The adsorbed reactant film 27 continues to reform on the surface of the COR reaction product 28 until the source of gases is depleted at which point the adsorbed reactant film 27 disappears as shown in FIG. 4F.
[0081] The result is that the HIPOX layer 18 has been removed from the base of the window W and has been replaced by the reaction product 28 . As stated above the same reaction occurs with only a small fraction of the TEOS layer 22 because of the differences in COR etching rates for TEOS layer 22 and HIPOX layer 18 that we have discovered experimentally.
[0082] The reaction product 28 continues to grow in thickness as the reactant gases from the adsorbed reactant film 27 continue to pass through the reaction product 28 to react with the underlying HIPOX layers 18 and the TEOS layer 22 . This reaction proceeds until after all of the base HIPOX (about 100 Å) at the bottom of the window 24 is removed; and continues until approximately the same thickness (about 100 Å) of the TEOS layer 22 is removed. Accordingly, since the TEOS layer was originally thicker than the HIPOX layer 18 , a thick TEOS layer 22 remains. At the end of the process shown in FIG. 4I, it is a requirement of the semiconductor product being manufactured that a thick TEOS layer 22 remains to serve as isolation between the extrinsic base 16 and the polysilicon of the emitter 31 which is added later to assure that the emitter 31 and the extrinsic base to do not become electrically short circuited together.
[0083] Next, referring to FIG. 4G, the device 10 of FIG. 4F is shown after transfer thereof into a heated chamber 70 that is heated to about 100° C. which includes exhaust line 74 , valve 76 , line 78 to pump 80 and an outlet 82 . An inlet line 67 , valve 68 and line 69 to chamber 70 are provided for introduction of gases into the chamber 70 , but at this time the valve 68 has been turned to the closed position. The window 24 ″ now reaches down to the top surface of the intrinsic base 16 .
[0084] Next, as illustrated in FIG. 4H, the device 10 of FIG. 4G is shown after completion of the precleaning process by removal of reaction product 28 . During heating of device 10 in chamber 70 , the reaction product 28 is removed (by evaporation at about 100° C. in this case) from the top surface of the base 16 at the bottom of the window 24 ′ and from the top surface of the TEOS layer 22 .
[0085] Finally, as illustrated in FIG. 4I, the device 10 of FIG. 4H is shown after the wafer temperature is raised to above the silane or dichlorosilane decomposition temperature, and valve 68 is opened to admit silane or dichlorosilane with optional dopants such as B 2 H 6 or arsine AsH 3 to form a polysilicon emitter 31 , shown having been formed from nucleation on the surface of the intrinsic silicon of the base 16 . The deposition continues until the polysilicon emitter 31 fills the window 24 ″ of FIG. 4H. As shown in FIG. 4I, the material of the emitter 31 is not shorted to the base layer 20 , and the emitter 31 (unlike the emitter 30 in FIG. 3E) does not undercut the sidewall spacers 26 .
[0086] (II) Geometric Tailoring of the HIPOX Opening
[0087] The solid COR reaction product 28 produces a self-limiting reaction, because during the interval between the results shown in FIGS. 4D and 4E the COR reaction product 28 (which as described above was formed below the adsorbed reactant film 27 ) impedes the diffusion of hydrogen fluoride and ammonia to the reacting surface of oxide (TEOS layer 22 and HIPOX layer 18 ). The self-limiting thickness of the reaction product 28 can be tuned by changing the reaction conditions. A higher pressure or lower temperature in chamber 44 increases the self-limiting thickness. Furthermore, the solid reaction product 28 occupies more volume than the silicon oxide of layers 22 / 18 which are being etched. This means that there is less etching at the exposed edges of the HIPOX layer 18 aside from the window 24 / 24 ′/ 24 ″. Etching is terminated at those edges. The self-limiting thickness of layer 28 can be tuned by changing reaction conditions.
[0088] The length of oxide tailing, from the edge of spacer 26 into window 24 , can be varied from undercut to about three times the thickness of the oxide layer 18 which is removed, with a maximum thickness of thermal oxide removal of about 250 Å in a single etching step.
[0089] (III) Other Features of the Process.
[0090] The combination of deposition and the COR etching processes of the present invention offers the advantage of tailoring the interaction between the processes. For example, the interaction between deposition conditions produces a surface of a given configuration provided by COR etch conditions clears away the HIPOX oxide 18 from the surface of the substrate 12 . As a result, a silicon oxide profile is produced in which the base 16 and the emitter 28 meet with the TEOS providing insulation between the extrinsic base 20 and the emitter 28 , thereby providing the desired configuration.
[0091] In particular, the Chemical Oxide Removal (COR) process is highly selective and self-terminating, thereby enabling controlled removal of thin layers of silicon oxide such as the HIPOX layer 18 to the degree desired and avoiding unintended undercutting by lateral removal of HIPOX 18 . By contrast, wet etching processes, do not offer the combination of self-termination and high selectivity and thus fail to offer an opportunity for tailoring the interaction between the deposition and the etching processes.
[0092] The mixture of reactive gases comprising HF from line 49 and NH 3 from line 53 initially forms the adsorbed reactant film 27 on the surface of the silicon oxide HIPOX layer 18 . Preferably, that mixture of reactive gases comprises a combination of HF (hydrogen fluoride) gas introduced through line 47 , valve 48 and line 49 into chamber 44 and ammonia (NH 3 ) gas introduced through line 51 , valve 52 and line 53 into the chamber 44 to remove the conformal HIPOX silicon oxide layer 18 exposing the surface of the crystalline silicon substrate 12 at the base of the window 24 ″ as seen in FIG. 4H.
[0093] Although the chemical reactions discussed herein are designed to remove silicon dioxide from silicon, other combinations of sources of chemical materials and other chemical steps can be employed. For instance, a number of different chemistries commonly used with aqueous solutions can be employed in the devices of the present invention designed for accurate etching.
[0094] Some of the specific sources include the gaseous vapor from solid ammonium bifluoride; a solution of HF, NH 3 , and H 2 O; separate sources of HF, NH 3 , and H 2 O; separate sources of HF and NH 3 ; a solution of NH 3 /H 2 O coupled with a gaseous or solution source of HF, and the like. In addition, HF and ammonia can be generated in a plasma from precursor gases. Solvents or solutions other than water can be used, e.g. alcohol can replace water. For another example, the silicon dioxide which forms on many silicides can react with condensed layers containing HF. Oxides other than silicon dioxide react with condensed layers containing HF and NH 3 or H 2 O. An example of that is that experiments have shown that HF vapor chemistries, including the vapor from ammonium bifluoride solid, remove oxides which incorporate germanium. Even pure germanium oxide will react.
[0095] There are a several low pressure or high temperature chemistries which use a source of a solid containing ammonium ions or separate sources containing ammonia and an acid. Ammonia is unique in that ammonia has a high vapor pressure while the ammonium ion containing solid which forms upon reaction with an acid is not particularly volatile. Thus, a number of aqueous chemistries which etch films besides oxides show analogous reactions in condensed films containing ammonia. When etching material, it is not necessary to etch a large amount of the material. For instance, removal of trace metal contamination may be achieved by the method of this invention.
[0096] Since high temperature annealing is not allowed after the base deposition in the bipolar fabrication, this vapor phase etch is well suited to preclean a silicon containing layer prior to silicon deposition, when a thick TEOS isolation layer is exposed. As a comparison, when wet etch is used, the removal of the TEOS is about 1000 Å if 100 Å HIPOX is to be removed, according to 10:1 ratio for annealed TEOS compared to HIPOX. There will not be enough TEOS left for isolation. The TEOS layer is damaged by the wet etch, resulting in shorting of the emitter to the base.
[0097] In alternative embodiments the pre-base cleaning process is similar to the above, except the transistor region is defined by exposed silicon between Shallow Trench Isolation (STI) regions. The STI regions can be damaged by the wet HF etch to produce the large divots. We have found that SiGe epitaxy can be successfully grown on the HF/ammonia cleaned surface. No defects are observed, and oxygen levels meet device requirements.
[0098] (IV) Solution of Exposed Oxide Attack Problem
[0099] Problem (A), as described above, is characterized by attack of exposed silicon oxide away from the base or emitter regions, creating shorts between emitter and base or producing detrimental topography in STI and elsewhere so that later silicidation of overlying silicon is difficult. This problem is effectively addressed by the use of an HF/ammonia vapor phase etch, since thermal silicon oxides have higher reaction rates in an HF/ammonia vapor phase etch than TEOS, or other types of silicon oxide (in contrast to the aqueous HF etch, where TEOS etches at a higher rate than thermal oxide). Accordingly, a thick TEOS isolation formed after a pre-emitter clean can be obtained by using a vapor phase etching of the base HIPOX, preventing the total removal of the isolation TEOS. An important advantage of this vapor phase etch is that no high temperature anneal is needed to harden the TEOS, avoiding any base degradation due to the dopant thermal diffusion. Similarly, there is equivalent or less attack of STI silicon oxides in a pre-base clean when compared with aqueous HF etches.
[0100] (V) Solution of Undercut Problem
[0101] The problem of undercutting of isolation features between base and emitter (problem (B) above) is solved because the HF and ammonia reaction with silicon dioxide creates a solid reaction product which expands in volume. The solid reaction product limits undercutting, because it serves as a diffusion barrier to the reacting HF and ammonia. The oxide structure underneath the nitride sidewall spacers is not damaged as in the aqueous etch process. In particular, the corner profile of the HIPOX after the vapor phase etch can be controlled with a tail-shaped structure, or a nearly vertical profile according to the amount of overetch, so that undercut is completely prevented. The prevention of the undercut by the vapor phase etch is extremely important in several modules such as the thermal silicon oxide removal before the base deposition. The undercut has also been linked to such problems as defects, leakage and unwanted topography.
[0102] Furthermore, a combination of polysilicon HIPOX and vapor phase etch will provide still better isolation, by preventing any potential leakage due to pipes generated in the TEOS, and at the same time ensure thick enough TEOS for isolation and reduction of capacitance.
[0103] (VI) Solution of Etch Penetration Problem
[0104] As stated above with regard to problem (C), with reference to FIGS. 2A and 2B, the problem is that defects and crevices in exposed silicon which later becomes the polysilicon gate for the accompanying CMOS can be penetrated by the aqueous etch thus attacking underlying gate oxide. In the preferred embodiment of the present invention, problem (C) is solved because the HF and ammonia reaction with silicon dioxide creates a solid reaction product which expands in volume and plugs any silicon oxide lined crevice. The advantage afforded by ths invention of plugging of crevices contrasts with an aqueous etch which dissolves any silicon oxide and readily penetrates any crevice.
[0105] (VII) Solution of Residual Oxide Problem
[0106] Residual silicon oxide from regrowth at the base/collector interface can produce defects during base epitaxy leading to leakage between an emitter and a collector (problem (D) described above). If a second aqueous treatment is used to remove the regrown silicon oxide, the problem is that silicon can also be removed leading to defects from roughness. These problems are avoided in the present invention, since the vapor phase oxide etch is integrated with the subsequent Si (or Si/Ge) growth process, so that the precleaning and growth processes are performed in a single vacuum system, thereby avoiding exposure to atmosphere and regrowth of native oxide. Because of the surprisingly large impact of silicon oxide regrowth in pre-base silicon oxide cleans, it is important to be able to integrate a silicon oxide removal chamber with the silicon or silicon/germanium growth chamber. The HF and ammonia reaction with silicon dioxide can take place at a low pressure (below 10 mTorr). It can be readily integrated with a silicon/SiGe growth chamber, in contrast to an aqueous clean or conventional vapor HF cleaning steps which generally take place at atmospheric pressure, or at pressures of at least several Torr.
[0107] Apparatus for Performing Integrated Etch/Evaporation/Deposition Processes
[0108] [0108]FIG. 5. and FIGS. 6 A- 6 C show tools with a handler able to move wafers from the HF and ammonia reaction, to product evaporation, to Si or Si/Ge deposition without breaking vacuum. The tool can combine product evaporation and Si or SiGe deposition chambers, and it can be of the single wafer or batch type. An important feature of the batch multichamber tool is a transportable cassette (of material compatible with both oxide etch and silicon deposition) which can be shuttled between chambers.
[0109] [0109]FIG. 5 is a diagram for a batch process apparatus, wherein a boat of wafers is shuttled between process chambers. For the SiGe applications, the wafers are reacted in the COR (HF and ammonia) reaction chamber 144 , then shuttled into chamber 170 for evaporation of the COR reaction product, then finally into the silicon/SiGe deposition chamber 175 . Transport rods TR are provided for pushing the cassette from chambers to a handler frog or turntable in central chamber 172 . Alternatively, chambers 170 and 175 may be one and the same chamber.
[0110] FIGS. 6 A- 6 C show an embodiment which uses a SiGe epitaxy system to process wafers in accordance with this invention. FIG. 6A shows a left elevation of the tool; FIG. 6B shows a front elevation and FIG. 6C shows a right elevation. While a horizontal orientation is shown, a vertical orientation is also possible.
[0111] [0111]FIG. 6B shows the load lock LL which is connected to the transport chamber which includes a left tube TTL reaching up to left transport chamber 171 and right tube TTR which reaches up to right transport chamber 145 . The left transport chamber 171 is connected to COR desorb chamber 170 which can be seen in the left elevation of FIG. 6A. Isolation valves IV isolate the various chambers so that shuttling can occur when a reaction is taking place in a reaction chamber, in the case of operation with multiple boats.
[0112] A wafer boat 90 (shown in five exemplary boat positions 90 A- 90 E) holds a batch of multiple wafers. The boat 90 is shuttled from load lock LL through the transport tubes TTL and TTR to transport chambers 171 and 145 by transport rods 91 or 92 . Then transport rods 94 or 95 respectively pick up the boat and shuttle the boat into the COR desorb chamber 170 or into the COR reaction chamber 144 . Chamber 170 may also be a SiGe or Si furnace.
[0113] The boat is shown in some of the different positions to which a boat may be transported from an atmospheric load lock LL to a central transport chamber with left tube TTL and right tube TTR, from which the boats are distributed to other attached process chambers.
[0114] The boat is transported laterally or diagonally in a transport chamber, then inserted into other chambers at right angles to the plane or line of movement inside the transport chamber. Insertion can be on one side or on both sides of the plane (and perpendicular to the plane) formed by movement of the wafer boat in the transport chamber. When insertion is on both sides, there will be process chambers on both sides of the transport chamber. The left side view in FIG. 6A shows the process chamber 170 only on the left side of the transport chamber. Transport rods can draw the boat into the chamber or can be on the opposite side of the transport chamber from the process chamber and can be pushed into the process chamber. Lift pins are incorporated as appropriate.
[0115] Some additional embodiments of the above-described apparatus are as follows. The transport chambers 171 / 145 may also include an atmospheric load lock. Alternatively, an atmospheric load lock may be provided on an end of each transport chamber (coplanar or collinear with the motion of the wafers in the transport chamber).
[0116] The central chamber 172 may include a rotary table which is a vertically moveable, with lift pins as appropriate; the rotary table may have indentations or recesses therein to facilitate handler access and/or grabbing and lifting the of the wafer boats. The wafers may be placed in the center of the rotary table, or off center so that more than one boat can occupy the rotary table simultaneously.
[0117] When the apparatus includes a central chamber, a transport rod may be mounted on the process chamber opposite the central chamber to draw the boat into the process chamber. Alternatively, a transport rod may be mounted on the central chamber opposite the process chamber, so that the wafers are pushed into the process chamber. In this case process chambers cannot be directly opposite each other.
[0118] Each type of transport can be fitted with a chamber as described in U.S. Pat. No. 5,636,320, or with a separate chamber for reaction and a separate chamber for elimination of the reaction product by evaporation or thermal desorption.
[0119] Each type of transport can be fitted with one or more chambers equipped to expose wafers to a mixture of HF and ammonia which is coupled, through the transport chamber, to one or more chambers equipped to remove, from the surface of the wafers, the products of the HF and ammonia reaction with silicon dioxide.
[0120] Other process chambers may be attached to the above-described tool to provide further process integration. Such chambers may include chambers for polysilicon deposition, advanced gate dielectric deposition, or conductor/contact liner CVD. In particular, one or more tube furnaces may be attached to the tool. The wafer boat orientation may be perpendicular or parallel to the transport direction. The plane of the wafers can be either perpendicular or parallel to the ground.
[0121] It should be noted that the temperature requirements for various stages of the above-described vapor phase etch process are different. The HF/ammonia reaction with oxide requires a stable chamber temperature near room temperature. Evaporation of the reaction product generally requires a chamber temperature near 100° C., so that the reaction product does not recondense on the chamber walls after it is evaporated from the wafers. Performing reaction and evaporation in separate chambers eliminates the extra time required for cooling the chamber after evaporation. In particular, there is a benefit when the HF/ammonia vapor phase etch tool is combined with a hot process furnace; the hot process furnace can then be used for evaporation of the reaction product.
[0122] While this invention has been described in terms of the above specific embodiments, those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims, i.e. that changes can be made in form and detail, without departing from the spirit and scope of the invention. Accordingly all such changes come within the purview of the present invention and the invention encompasses the subject matter of the claims which follow.
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An oxide etch process is described which may be used for emitter and base preparation in bipolar SiGe devices. The low temperature process employed produces electrical insulation between the emitter and base by a COR etch which preserves insulating TEOS glass. The insulating TEOS glass provides reduced capacitance and helps to achieve high speed. An apparatus is also described for practicing the disclosed process.
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BACKGROUND ART
Ink stamping devices for various industrial and commercial applications having a variety of features are well-known in the prior art. Some of the applications for such devices include assembly line manufacturing processes wherein various parts and sub-assemblies produced in high volume require identifying markings, such as part numbers for example. Other applications include marking containers or boxes with certain indicia such as contents, production information, shelf life and the like.
Many of the automated ink marking devices are relatively complex and expensive, such as sophisticated printers and the like. A relatively low cost contact ink printer capable of high volume and clear strong imprints is disclosed in U.S. Pat. No. 4,718,341. Reliable high volume printers generally include a stamping die which must be returned to an ink recharging position engaging a supply of ink to assure that a clear imprint is placed on the workpiece in a reliable manner.
While a printer such as disclosed in U.S. Pat. No. 4,718,341 works quite satisfactorily with respect to reliability and marking, it requires a significant amount of downtime in applications which require relatively frequent changes in the color or type of ink used or when the ink pad becomes in need of replacement for any other reason.
In prior contact stamping devices of this type, the whole ink supply assembly is required to be removed in order to implement a change of the color or the type of ink for any reason and then repositioned on the machine. Then it must again be attached to the frame and precisely registered in a proper sealed relationship with the stamping die assembly to avoid poor marking performance and to prevent dry out of the ink supply during non-use. This time consuming procedure results in costly downtime which limits production capacity of the line. If this time-consuming procedure is not done properly, poor quality marking may occur and result in further lost production time while corrective procedures are carried out.
BRIEF DISCLOSURE OF INVENTION
The present invention relates generally to high speed, high volume contact ink stamping devices which are adaptable to volume production lines for marking various parts or subassemblies or product packages. In particular, the present invention relates to those contact ink printers having a reciprocating stamping device movable between an ink recharging position and a stamping or marking position and which include an improved ink reservoir assembly constructed to permit changing of the ink supply pad as needed in a efficient and conveniently fast manner.
In a reliable, high speed contact ink stamping device of the type referred to herein, the maintenance of a sealed relationship between the stamping die assembly and the ink supply mean is important to prevent drying out of the ink pad during periods of non-use. However, such sealed contact requires rather precise alignment between the ink reservoir assembly and the stamping die. A contact ink printer which effectively provides such alignment is disclosed in my prior U.S. Pat. No. 4,718,341.
The present invention is characterized by an ink supply reservoir assembly which includes a mounting bracket and a removably mounted ink pad holder and ink supply bottle or reservoir. The ink pad holder and ink supply bottle are constructed to cooperate with the bracket to permit simple, fast and efficient change of the ink supply to the stamping die without disturbing the original precisely registered position between the bracket and the stamping die assembly. This is accomplished by providing the bracket with a recess for removably accepting the ink pad holder in which an ink pad is disposed. Upon mounting the ink pad holder into the recess, the ink pad is disposed adjacent to an access opening in the bracket which is surrounded by an elastic seal which is sealingly engaged by the periphery of the stamping die assembly while the printing surface engages the ink pad to be re-charged with ink.
The bracket and its elastic seal surrounding the access opening are separable from the ink pad holder and supply bottle, so that the latter may be removed and quickly replaced without any change of position of the bracket and its seal.
This construction permits the user to easily and quickly switch one ink pad holder and supply bottle combination for another to change the color or type of ink or to change the ink pad with minimum downtime and without risk of losing the established registered position with the stamping die.
In field operations wherein various marking runs of workpieces require different color indicia or grades of ink, the savings in time compared with the prior art is very dramatic. Such time saving is further enhanced by the fact that the chance for human error is essentially eliminated with respect to re-establishing the desired registered, sealed position with the stamping die.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a front elevational view of a contact ink stamping apparatus which includes the novel ink supply assembly constructed in accordance with the present invention;
FIG. 2 is side elevational view of the apparatus shown in FIG. 1; and
FIG. 3 is a partial perspective view of the apparatus shown in the preceding figures illustrating the components of the novel bracket and ink pad holder assembly in exploded relationship apart from the remainder of the ink stamping apparatus and illustrating the position of the ink pad in the ink pad holder in a partial break away view of one wall of the holder.
FIG. 4 is a perspective view of the ink pad holder shown in FIG. 3 with the ink pad shown in exploded relationship to the holder.
In describing the preferred embodiment of the invention which is illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to the specific terms so selected and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the word connected or terms similar thereto are often used. They are not limited to direct connection but include connection through other elements where such connection is recognized as being equivalent by those skilled in the art.
DETAILED DESCRIPTION
A contact ink stamping apparatus provided with an improved ink re-charging supply assembly constructed in accordance with the present invention is shown in FIGS. 1 and 2. For illustrative purposes, the contact stamping device shown is essentially identical to that shown and described in my prior patent, U.S. Pat. No. 4,718,341, except a it relates to the construction of the novel ink re-charging assembly which replaces the ink supply member shown in that patent. In a fully assembled condition, the stamping apparatus shown in FIG. 1 functions essentially identical to that described in U.S. Pat. No. 4,718,341 with regard to the movement and operation of the stamping die between the ink re-charging position and the stamping position wherein indicia is printed on a workpiece.
Therefore for the purposes of brevity, the ink stamping apparatus and its functions will be described in more general terms herein as one skilled in the art referencing the above-identified patent will be sufficiently informed and understand the operation thereof in connection with the present invention disclosed herein.
With reference to FIGS. 1 and 2, the contact ink stamping apparatus includes a vertically extending base or frame means, indicated generally at 20 and includes side walls members 21. A conventional cylinder and piston assembly, partially shown and indicated generally at 22, is conventionally mounted on the top of frame means 20.
Cylinder and piston assembly 22 includes a mounting block 23 fixed in position on the upper portion of frame means 20 by threaded fasteners such as 24 and 26.
An ink re-charging assembly indicated generally at 28 and constructed in accordance with the present invention includes an ink re-charging bracket member 29 which is fixed to the frame means via a pair of machine screws such as 31, which pass through holes in a strap member 33 extended across the side walls 21 of frame 20. Screws 31 are threadably received by threaded holes provided in bracket member 29 as described later herein. Upon positioning the bracket 29 and its seal 35 in position relative to the stamping die assembly, screws 31 may be tightened to fix bracket 29 into the desired sealed relationship relative to the stamping die.
With reference to FIG. 3, bracket member 29 includes a top and bottom opening, 30 and 39, formed by surrounding side walls 32 which are adapted to slideably receive an ink pad holder component, indicated generally at 34, in a relatively close fitting relationship.
The cavity formed between said side walls 32 and the top and bottom openings is configured to wholly receive ink pad holder member 34. The bottom opening 39 is surrounded along its lower edge by a resilient gasket or seal 35 fixed thereto by a suitable adhesive. The opening 39 is sized to accept the working surface of a die stamp assembly which carries a die stamp working or printing surface.
A pair of horizontally spaced threaded holes, such as at 36, are provided in the rear wall 32 and receive the screws 31, as described earlier herein, to accomplish the mounting of bracket 29 to the frame. Other conventional means and well-known methods could be employed to adjustably mount bracket 29 in the desired position without departing from the spirit of the present invention.
Preferably the rear wall 32 is provided with an upwardly extended flange-like portion 38 and a thicker lower portion to provide additional rigidity. The increased thickness merely serves to provide greater depth to the threaded holes 36 to allow greater threaded engagement for screws 31.
Ink pad holder 34 includes a generally rectangular block-like portion 40 and a neck portion 42 provided with a narrowed section 44.
Block-like portion 40 is provided with a bottom surface having an ink pad receiving recess 45 configured to receive a conventional ink pad 46, preferably conventionally formed of an absorbent flexible material. Recess 45 includes a surrounding, relatively thin lip portion 48 which serves to retain ink pad 46 within the confines of recess 45, yet permitting access to the major portion thereof through the outwardly facing portion of the recess.
Ink pad 46 is sized to conform snugly within recess 40 and is inserted wholly therein by urging the outer edges or periphery thereof past the lip portion 48.
A supply of ink is conventionally provided to the ink pad via a passageway, not shown, which is conventionally drilled or cast through neck portion 42 and into block portion 40 in communication with recess 45. A conventional elbow fitting 49 is extended into passageway and is conventionally threadably connected to an ink bottle or container 50. An absorbent wick 52, which may consist of the same material as ink pad 46, is extended from bottle 50 through the fitting 49 and the ink passageway to a position within recess 45 in contact with the upper surface of ink pad 46. This provides a constant ink supply to pad 46 from bottle 50 via capillary action through the wick 52.
This form of communication of ink from the supply bottle to the ink pad is identical to that shown in my prior patent U.S. Pat. No. 4,718,341 and has been used in other prior art contact ink stamping devices.
The opening to the drilled passageway may be threaded, if desired, to receive fitting 49, however, it is preferred to provide a set screw, such as 54, mounted in a threaded hole which intersects the drilled passageway to secure fitting 49 in a very easily removable fashion.
As best seen in FIG. 3, narrowed portion 44 of neck portion 42 is configured to be received in a cut-out portion or notch 43 provided in one of the side walls 32 of bracket member 29. Preferably, the depth of ink pad holder 34 within bracket 29 is releasably fixed in an adjustable manner by a conventional thumb screw 37 mounted in a thread bore, not shown, provided in wall 32 of bracket 29.
A slight vertical groove 56 is provided in the front wall of holder 34 to receive the end of set screw 37 in force transmitting engagement to releasably fix holder 34 in a selected position. Any metal deformation which might occur is confined to groove 56 and therefore will not interfere in the close-fit relationship between the walls of bracket 29 and ink pad holder 34. Preferably a clearance exists between narrowed portion 44 and the bottom of notch 43 when holder 34 is initially mounted in bracket 29.
The vertical extent of groove 56 permits a sufficient degree of vertical adjustment of the depth of holder 34 within bracket 29 to provide for fine adjustment of the position of ink pad 46 relative to the fixed position of the stamping die disposed in the ink recharging position. After repeated contact, ink pad 46 may become slightly compacted. In this event, lowering of holder 34 becomes desirable to adjust the position of ink pad 46 to assure the stamping die continues to make good contact with ink pad 46 to receive sufficient ink to form a clear, strong mark.
Referring again to FIGS. 1 and 2, a slide block 58 is mounted to the lower end of the piston of cylinder and piston assembly 22 in a conventional manner and includes vertically extending ribs slideably mounted in vertical tracks provided on the opposing inner surfaces of walls 21 such as described in U.S. Pat. No. 4,718,341. A pivot block 60 carries a die stamp assembly 62 provided with a working surface carrying the indicia desired to be printed on the workpiece.
Pivot block 60 and its operation are fully described in my U.S. Patent identified above and incorporated by reference herein and therefore will not be described in detail. However, the result of such construction provides that the die stamp assembly 62 having its working surface carrying indicia, not shown, are caused to reciprocate between an ink charging position and a printing position. In many applications it is desirable to provide a removable mounted die stamp carrying printing indicia to the die stamp assembly 62 such as using a releasable clamp holder fixed to a removable die stamp such as schematically represented at 61. However, such construction is well-known in the prior art and is not described herein. The ink charging position is defined with the die stamp assembly and its working surface disposed in contact with ink pad 46 and with the periphery of the die stamp assembly 62 disposed in sealed engagement with gasket 35. The printing position is shown in ghost lines in FIGS. 1 and 2. The die stamp assembly 62 is pivoted 180 degrees during its travel between these two positions to reverse the working surface accordingly between the ink recharging position and the stamping position engaging a workpiece, such as at 70.
As the die stamp assembly 62 is actuated to reciprocate between these described positions, the construction of the stamping apparatus, as disclosed in U.S. Pat. No. 4,718,341, provides for the stamping surface to be located in a precise parallel position to the ink pad 46 and the workpiece 70 to assure a clear and complete print is made.
As previously mentioned herein, this parallel position with respect to the ink re-charging assembly 28 and particularly to the gasket 35 and ink pad 46 is desirable to assure the working surface carrying indicia receives a complete supply of ink on each cycle of die stamp assembly 62 and also to assure that a good seal is formed between the die stamp assembly and gasket 35 to prevent drying out of ink supply during periods of non-use. If the registry between die stamp assembly and gasket 35 is not sufficient to form a good seal, the quick drying ink used will dry in the ink pad during periods of non-use. Then start-up operations are unnecessarily delayed because the ink pad and, during longer periods, the supply bottle may become dry and require re-charging.
Using the prior art construction, such as shown in U.S. Pat. No. 4,718,341, any condition requiring re-charging or changing of the ink pad 46 required that the whole ink reservoir assembly be removed from the frame. This represented a relatively time consuming process. Further, such removal necessarily dictated that the whole reservoir assembly had to be replaced on the frame and carefully readjusted to properly register with the die stamp assembly in the recharging position to re-establish the desired parallel and sealed relationship.
In some applications, changes of ink color or type are relatively infrequent and the time consumed in such procedure is therefore not as bothersome. However, certain applications require frequent changes in the color or type of ink employed and particularly emphasize any time consuming inefficiency in making such changes. Prior to the present invention, such applications often dictated the use of a very expensive, highly sophisticated printing apparatus capable of changing ink color or types quickly to reduce any lost production time.
However, utilizing the apparatus of the present invention eliminates any such disadvantage of the relatively inexpensive contact ink printing apparatus of the type disclosed herein. Since the ink pad holder 34 is separable from bracket 29 and easily removed, the user may maintain a supply of several such holders 34, the associated ink pads 46 and bottles 50 to permit quick replacement of another color or type of ink as required in a given application. Such components are, in themselves, relatively inexpensive.
To implement a change to a different color or type of ink, the user merely loosens thumb screw 37 and lifts ink pad holder 34 upwardly using knob 41 conventionally attached to the top of block portion 40. Bracket 29 remains in its original registered position and is undisturbed during any change of ink pad holder 34.
Another identically constructed ink pad holder 34 carrying a new ink pad 46, wick 52 and supply bottle 50 which is charged with the desired type of ink, is quickly replaced by inserting it into the top opening 30 of bracket 29 as previously described. Holder 34 is lowered into bracket 29 to the desired depth associated with full contact between ink pad 46 and working surface of die stamp assembly 62. This may be easily accomplished by lowering holder 34 into bracket 29 while die stamp assembly 62 is fully seated in its re-charging position in sealed engagement with gasket 35. The user then simply tightens thumb screw 37 to fix this position wherein the working surface of die stamp assembly 62 fully contacts ink pad 46. Any further fine adjustment of the position of holder 34 is accomplished as previously described.
As is well-known in the trade, it is desirable to charge or saturate ink pad 46 initially directly by pouring ink from bottle 50, or another source of ink, on ink pad 50, prior to placing the holder 34 within bracket 29. Ink pad 46 will maintain a sufficient charge of ink via capillary action through wick 52 inserted into ink bottle 50. From the foregoing description, it should be readily appreciated that the apparatus of the present invention provides a contact ink stamping apparatus capable of handling a variety of applications, particularly those requiring frequent changes in the color or type of ink required, with ease and a minimum loss of production efficiency.
While certain preferred embodiments of the present invention have been disclosed in detail, it is to be understood that various modifications may be adopted without departing from the spirit of the invention or scope of the following claims.
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An improved automatic contact ink stamping apparatus which is characterized by a multipart ink re-charging assembly which facilitates the changing of the supply of ink or the ink pad in a quick and easy manner without disturbing the fixed registration position between the ink assembly and the stamp mounting plate. The contact stamping apparatus disclosed in the type wherein the die stamp is reciprocated between an ink re-charging and a stamping position. The ink re-charging assembly includes a mounting bracket fixed to a support base of the apparatus which is conformed to removably receive an ink pad holder. The ink pad holder includes an ink pad which is positioned therein to engage the work surface of the die stamp when it is located in the re-charging position. The ink pad holder can be easily removed in a simple manner and replaced for any reason without removing and adjusting the registered and sealed initial position of the bracket relative to the die stamp.
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BACKGROUND OF THE INVENTION
This invention relates generally to turbine engines and, more particularly, to apparatus and methods for preventing stall in a compressor.
A turbine engine typically includes a fan in front of a core engine having, in serial flow relationship, a low pressure compressor, or a booster, and a high pressure compressor. The low pressure compressor and the high pressure compressor each include an inlet section and a discharge section.
During engine power reductions, the inlet section of the high pressure compressor may generate an airflow blockage resulting from a flow differential between airflow through the high pressure compressor inlet section and the airflow through the booster discharge section. The airflow blockage generates a back pressure in the booster which causes the booster operating line to migrate closer to a stall limit. Migration of the booster operating line closer to the stall limit restricts the operating range of the turbine engine because less air continues to flow through the booster.
If the booster stalls, loud banging noises and flames or smoke may be generated at the booster inlet and/or discharge section. A booster stall condition results in excessive wear, degradation of performance, and a reduction in engine reliability and durability. In order to compensate for booster stall, the booster is typically over constructed, leading to more parts that in turn make the booster, and the resulting engine, heavier.
Booster stall is mitigated in existing engines by the use of complex variable bleed doors, or valves, which open during unsteady airflow conditions and allow a portion of the booster airflow to bypass the high pressure compressor. However, the bleed doors may fail or malfunction due to the complexity of the doors and valves.
Accordingly, it would be desirable to provide efficient booster stall protection without the added complexity of variable bleed doors. Additionally, it would be desirable to provide improved reliability of booster stall protection.
BRIEF SUMMARY OF THE INVENTION
A booster which includes a stator casing, a rotor shroud, and stator and rotor hub treatments extends the booster stall limit capability, and eliminates the need for variable bleed, or bypass, doors. More particularly, and in an exemplary embodiment, the booster includes a passageway which extends from a higher pressure portion of the booster to a lower pressure portion of the booster. The passageway includes angular slots which extend along an airflow path from the higher pressure portion of the booster to the lower pressure portion of the booster.
In operation, an airflow enters the passageway at a higher pressure portion of the booster. The airflow travels through the passageway from the higher pressure portion of the booster to the lower pressure portion of the booster, and expends energy and decreases in pressure while traveling through the passageway. The airflow then exits the passageway at the lower pressure portion of the booster and returns to the airflow path.
Recirculation of the airflow from the higher pressure portion of the booster to the lower pressure portion of the booster extends a booster stall free operating region and reduces the likelihood that the booster will reach a stall limit during engine power reductions. As back pressure diminishes, the recirculation lessens and the booster returns to a more normal operation. By eliminating the bypass doors or valves, the passageway increases engine and booster stall protection reliability.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a turbine engine including a low pressure compressor;
FIG. 2 is an enlarged axial sectional view of the low pressure compressor shown in FIG. 1 including a recirculating passageway;
FIG. 3 is an enlarged perspective view of a portion of the recirculating passageway shown in FIG. 2;
FIG. 4 is an enlarged axial sectional view of the low pressure compressor shown in FIG. 1 including a plurality of circumferential grooves; and
FIG. 5 is an enlarged axial sectional view of the low pressure compressor shown in FIG. 1 including an alternative recirculating passageway.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a cross sectional view of a turbine engine 10 symmetrical about a central axis 20 . Engine 10 includes, in serial flow communication, a front fan 30 , a multistage low pressure compressor, or booster 40 , a multistage high pressure compressor 116 which supplies high pressure air to a combustor 120 , a high pressure turbine 130 , and a low pressure turbine 140 .
During operation of engine 10 , air flows downstream through fan 30 and into multistage booster 40 . The booster compresses the air and the air continues to flow downstream through high pressure compressor 116 where the air becomes highly pressurized. A portion of the highly pressurized compressed air is directed to combustor 120 , mixed with fuel, and ignited to generate hot combustion gases which flow further downstream and are utilized by high pressure turbine 130 and low pressure turbine 140 to drive high pressure compressor 116 , front fan 30 , and booster 40 , respectively.
FIG. 2 illustrates a portion of the engine shown in FIG. 1 . As shown in FIG. 2, booster 40 includes a plurality of stator vanes 42 and a plurality of rotor blades 44 surrounded by a stator casing 46 and a plurality of rotor shrouds 48 . A first passageway, or flow path, 50 extends through booster 40 and is formed, and defined, by stator vanes 42 , rotor blades 44 , stator casing 46 , and rotor shrouds 48 .
A second passageway, or flow path, 52 in booster 40 extends through a portion of rotor shroud 48 adjacent a forward rotor blade 54 . Second passageway 52 is in flow communication with flow path 50 . Booster 40 includes a first wall 56 , stator casing 46 , a leading edge 60 , and a trailing edge 62 which form second passageway 52 . First wall 56 and stator casing 46 extend substantially 360 degrees around central axis 20 of turbine engine 10 (shown in FIG. 1 ). First wall 56 is connected to leading edge 60 and trailing edge 62 , which are also connected to stator casing 46 .
Forward rotor blade 54 also includes a leading edge 64 and a trailing edge 66 . A plurality of openings 68 extend through stator casing 46 and are in flow communication with second passageway 52 . Openings 68 in stator casing 46 extend from leading edge 60 to a portion 69 of rotor blade 54 between leading edge 64 and trailing edge 66 . First passageway 50 of booster 40 further includes an inlet, or a lower pressure portion, 70 and a discharge, or a higher pressure portion, 72 .
In operation, airflow moves downstream through booster 40 along flow path 50 and increases in pressure and temperature. When fuel and high pressure airflow are decreased to combustor 120 (shown in FIG. 1 ), fan 30 (shown in FIG. 1 ), booster 40 , and high pressure compressor 116 (shown in FIG. 1) decelerate. Due to a lower inertia and a higher pressure ratio, high pressure compressor 116 decelerates faster than fan 30 and booster 40 . The faster deceleration of high pressure compressor 116 generates an airflow blockage that results in an increased back pressure at discharge 72 , forcing an operating line of booster 40 to migrate towards a stall limit line.
The increased back pressure causes a portion of the high pressure airflow to recirculate and exit passageway 50 at a higher pressure portion of booster 40 through openings 68 and enter passageway 52 . The recirculating airflow re-enters flow path 50 at a lower pressure portion of booster 40 , i.e., extends the booster stall limit line. Recirculating a portion of the high pressure airflow beyond the raised operating line of booster 40 allows airflow to freely move from the higher pressure portion of booster 40 to the lower pressure portion of booster 40 . The amount of recirculation varies depending on the amount of booster back pressure. For example, an increased booster back pressure results in an increased recirculating airflow and a decreased booster back pressure results in a decreased recirculating airflow.
FIG. 3 illustrates a perspective view of openings 68 shown in FIG. 2 . As shown in FIG. 3, openings 68 in stator casing 46 include a plurality of angled slots 74 which extend from leading edge 60 to portion 69 .
In operation, high pressure airflow enters angled slots 74 between rotor blade leading edge 64 and portion 69 . The high pressure airflow travels through passageway 52 (shown in FIG. 2) until the airflow exits passageway 52 through angled slots 74 at leading edge 60 . The airflow then travels downstream in flow path 50 and increases in pressure.
FIG. 4 illustrates a portion of booster 40 including a plurality of circumferential grooves 76 . Circumferential grooves 76 extend from leading edge 60 to trailing edge 62 in rotor shroud 48 . Booster 40 includes first wall 56 and circumferential grooves 76 extend from opening 68 to first wall 56 .
In operation, a portion of a wake fluid enters a downstream circumferential groove 76 between rotor blade leading edge 64 and trailing edge 66 at openings 68 when the high pressure airflow reverses flow direction and flows upstream in booster 40 . The wake fluid then progresses upstream in booster 40 and enters an adjacent groove 76 . The upstream progression of the wake fluid continues until either the high pressure airflow again flows downstream or the wake fluid extends upstream beyond grooves 76 and booster stall occurs. Grooves 76 extend the stall line of booster 40 and increase the operating range of booster 40 .
FIG. 5 illustrates a booster 77 including a plurality of hub stator vanes 78 and a plurality of hub rotor blades 80 surrounded by a hub stator casing 82 and a plurality of hub rotor shrouds 84 .
A first passageway, or flow path, 86 extends through booster 77 and is formed, or defined, by hub stator vanes 78 , hub rotor blades 80 , hub stator casing 82 , and hub rotor shrouds 84 . Booster 77 further includes a second passageway 88 and an aft hub rotor blade 90 connected to a rotor shaft 91 . Second passageway 88 extends through a portion of rotor shaft 91 . Rotor shaft 91 includes a first wall 92 and a second wall 94 which extend 360 degrees. Second passageway 88 is in flow communication with flow path 86 and is bounded by first wall 92 and second wall 94 .
Rotor shaft 91 further includes a leading edge 96 and a trailing edge 98 . First wall 92 is connected to leading edge 96 and trailing edge 98 which are connected to second wall 94 . First wall 92 , second wall 94 , leading edge 96 , and trailing edge 98 form second passageway 88 . Aft hub rotor blade 90 , located in the hub of booster 77 , includes a leading edge 100 and a trailing edge 102 . Second wall 94 comprises a plurality of openings 104 in flow communication with second passageway 88 and an opening 106 in hub stator vane 78 adjacent aft hub rotor blade 90 .
In one embodiment, openings 104 and 106 in second wall 94 and in hub stator vane 78 adjacent aft hub rotor blade 90 comprise a plurality of circular apertures (not shown). Booster 77 also includes an inlet 112 located at an area of lower pressure, and a discharge 114 located at an area of higher pressure.
The embodiment of Booster 77 shown in FIG. 5 maintains stability in boosters that have their aerodynamic stability limitations in the hub region. When booster 77 has raised operating line conditions, increased recirculation through second passageway 88 keeps the hub region pressure at trailing edge 102 of hub rotor blades 80 from attaining a stability limit level. This increased recirculation maintains booster 77 in a stable, i.e., a stall free, operation at the raised operating line condition.
The recirculation passageway is formed in the existing structure of the turbine engine and adds minimal cost and complexity to the booster. The inclusion of the recirculating passageway in the booster protects against booster stall and improves the reliability of operation when compared to variable bleed valves or doors which may stick or function improperly.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A recirculation passageway for a turbine engine provides stall protection in a booster by directing high pressure airflow from a flow path of the booster to the passageway. The high pressure airflow loses energy and decreases in pressure while traveling through the passageway until re-entry into the booster flow path. The airflow recirculates in the passageway until the airflow is discharged through a high pressure compressor.
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RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Ser. No. 61/366,162, filed Jul. 21, 2010, which is herein incorporated by reference.
BACKGROUND
[0002] 1. Technical Field The present disclosure relates to an energy conversion device. More particularly, the present disclosure relates to a photovoltaic panel and a method of manufacturing the photovoltaic panel.
[0003] 2. Description of Related Art
[0004] Photovoltaic (PV) devices convert light energy, particularly sunlight, into electrical energy, without producing any greenhouse gases during the conversion process, therefore may realize a green energy environment. The electrical energy generated by the photovoltaic devices can be used for all kinds of applications as those achieved by batteries or existing power generators. Recently, along with the progresses and developments of photovoltaic technology, the cost of the PV devices takes a significant price drop thereby rendering PV devices more affordable and more popular in the consumer market. For example, the PV devices can now be found on the residence rooftops and the external walls of buildings, as well as in varies electronic products such as mobile phones, personal digital assistants, digital watches, and laptops.
[0005] Generally, a PV device includes a PV cell of semiconductor materials disposed on a front substrate of the device. In order to protect the PV cell, a polymer layer, such as a layer of ethyl vinyl acetate (EVA), is placed on the PV cell. However, while the. PV device is used in an outdoor environment, to maximize its exposure to the sunlight, the moisture from the environment in the form of rain, fog, or even snow becomes a major stimulant that causes EVA delamination, metal oxidation, corrosion and other quality problems. The moisture intrudes into the PV cell through the lateral sides and the back substrate of the PV device, especially when the back substrate is in the form of a polymer back sheet. The moisture gradually penetrates through the EVA and/or the back sheet for a certain time period and eventually gets to contact with the PV cell, which ultimately leads to serious power degradation of the PV is device.
[0006] It is therefore an important issue for the manufacturers to improve the resistance of the PV device against moisture.
SUMMARY
[0007] A photovoltaic panel and a method of manufacturing the photovoltaic panel are provided in the disclosure to solve the problems caused by the moisture intrusion to the photovoltaic cell.
[0008] According to one aspect of the disclosure, a photovoltaic panel is provided. The photovoltaic panel includes a front substrate, a photovoltaic cell, a moisture absorbing layer, a back substrate, and a sealant. The photovoltaic cell is disposed on the front substrate. The moisture absorbing layer covers the photovoltaic cell. The back substrate is disposed on the moisture absorbing layer. The sealant is disposed between the front substrate and the back substrate and is positioned at or near the edges of the front substrate and the back substrate. The sealant substantially seals the photovoltaic cell and the moisture absorbing layer therein.
[0009] In one embodiment of the disclosure, the photovoltaic panel optionally includes an encapsulant disposed between the cell and the moisture absorbing layer to encapsulate the cell.
[0010] In another embodiment of the disclosure, the photovoltaic panel optionally includes an encapsulant disposed between the moisture absorbing layer and the back substrate to encapsulate the cell.
[0011] In a further embodiment of the disclosure, the moisture absorbing layer optionally includes a micro-porous desiccant structured as a molecular sieve. The pore size of the micro-porous desiccant ranges from about 0.3 nm to about 1 nm, and the micro-porous desiccant includes zeolite.
[0012] In yet another embodiment of the disclosure, the moisture absorbing layer optionally includes an encapsulant and a micro-porous desiccant blended in the encapsulant. The micro-porous desiccant includes zeolite, and the encapsulant includes ethyl vinyl acetate.
[0013] According to another aspect of the disclosure, a method of manufacturing a photovoltaic panel is provided. The method includes the following steps: forming a photovoltaic cell on a front substrate; applying a moisture absorbing layer covering the photovoltaic cell; applying a sealant at or near the edges of the front substrate; and securing a back substrate to the front substrate such that the photovoltaic cell and the moisture absorbing layer are situated within an enclosed space formed by the front substrate, the back substrate and the sealant.
[0014] In one embodiment of the disclosure, the step of applying the moisture absorbing layer optionally includes a step of laminating a film of a micro-porous desiccant onto the cell. The micro-porous desiccant includes a getter composite film containing zeolite nanoparticles.
[0015] In another embodiment of the disclosure, the step of applying the moisture absorbing layer optionally includes a step of laminating a film of an encapsulant and a micro-porous desiccant blended in the encapsulant onto the cell. The encapsulant includes ethyl vinyl acetate, and the micro-porous desiccant includes zeolite.
[0016] In the foregoing, the photovoltaic cell in the photovoltaic panel is protected not only by the sealant but also by the moisture absorbing layer. By trapping the water molecules of the moisture in the moisture absorbing layer, the moisture intrusion into the photovoltaic cell is prevented, and the power degradation of the photovoltaic cell is avoided.
[0017] It is to be understood that both the foregoing general description and the following detailed description are by examples, and are intended to provide further explanation of the disclosure as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The disclosure can be more fully understood by reading the following detailed description of the embodiments, with reference made to the accompanying drawings as follows:
[0019] FIG. 1 is a cross-sectional view of a photovoltaic panel according to one embodiment of the disclosure;
[0020] FIG. 2 is a cross-sectional view of a photovoltaic panel according to another embodiment of the disclosure;
[0021] FIG. 3 is a cross-sectional view of a photovoltaic panel according to a further embodiment of the disclosure; and
[0022] FIG. 4 is a flow chart of a method of manufacturing a photovoltaic panel according to one embodiment of the disclosure.
DETAILED DESCRIPTION
[0023] The photovoltaic panel and the method of manufacturing the photovoltaic panel utilize a moisture absorbing layer to trap moisture and pollutant gases. The problems of material delamination, erosion, and power degradation of the is panel can therefore be prevented. Thus the life span of the panel is extended.
[0024] FIG. 1 is a cross-sectional view of a photovoltaic panel according to one embodiment of the disclosure. The photovoltaic panel 100 includes a front . substrate 110 , a photovoltaic cell 120 , a moisture absorbing layer 140 and a back substrate 160 . The photovoltaic cell 120 is disposed on the front substrate 110 , and the moisture absorbing layer 140 covers the photovoltaic cell 120 . The back substrate 160 is parallel to the front substrate 110 , and the photovoltaic cell 120 and the moisture absorbing layer 140 are situated between the front substrate 110 and the back substrate 160 .
[0025] In one embodiment, the material of the front substrate 110 is exemplified by a transparent conductive oxide (TCO) glass. However, the front substrate 110 is not limited to the TCO glass. Alternatively, the front substrate 110 can also be made of appropriate polymer films, such as DuPont™ Teflon® films, DuPont™ Teonex® polyethylene naphthalate (PEN) films and DuPont™ Melinex® ST polyester films. Practically, any other appropriate materials that are of high transmittance, light weighted, flexible, good UV resistance, and/or sufficient mechanical strength can be used in manufacturing the photovoltaic panel 100 of the present disclosure.
[0026] On the other hand, the photovoltaic cell 120 is exemplified by a thin film photovoltaic cell having multiple metal layers deposited on the front substrate 110 . Exemplary materials of the metal layers include, but are not limited to, amorphous silicon, cadmium diselenide (CdS), cadmium telluride (Cd/Te), copper indium diselenide (CIS), and/or copper indium gallium diselenide (CIGS). The photovoltaic cell 120 may be deposited by known depositing methods, such as chemical vapor deposition (CVD), physical vapor deposition (PVD), sputtering, or any other methods known to a person skilled in the art.
[0027] In the present embodiment, the moisture absorbing layer 140 includes a micro-porous desiccant structured as a molecular sieve. The micro-porous desiccant includes zeolite that is a crystalline aluminosilicate material serving as the molecular sieve to trap moisture and even pollutant gases like nitride compounds. The pore size of the micro-porous desiccant ranges from about 0.3 nm to about 1 nm, so as to trap water molecules and other molecules harmful to the photovoltaic cell 120 . Practically, the pore size of the micro-porous desiccant can be 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9 or 1.0 nm.
[0028] Although the moisture absorbing layer 140 is exemplified by including zeolite in the present embodiment, it is not limited thereto. Other crystalline materials having uniform molecular-scale pores to form a molecular sieve and to separate molecules based on sizes, shapes and polarities, may be used in the photovoltaic panel 100 of the present embodiment.
[0029] As shown in FIG. 1 , the moisture absorbing layer 140 covers the photovoltaic cell 120 . More specifically, the moisture absorbing layer 140 overlays a top surface 121 of the photovoltaic cell 120 , such that the moisture penetrating through the back substrate 160 can be trapped by the moisture absorbing layer 140 . In this manner, the photovoltaic cell 120 is protected from the moisture intrusion. The problems of moisture penetrating through the back substrate 160 can be prevented, therefore would increase the life span of the photovoltaic panel 100 .
[0030] In addition to the above described front substrate 110 , photovoltaic cell 120 , moisture absorbing layer 140 and back substrate 160 , the photovoltaic panel 100 of the present embodiment further includes an encapsulant 130 and a sealant 150 . In one embodiment, the encapsulant 130 is disposed between the photovoltaic cell 120 and the moisture absorbing layer 140 to encapsulate the photovoltaic cell 120 . The sealant 150 is disposed between the front substrate 110 and the back substrate 160 , and is positioned at or near the edges of the front substrate 110 and the back substrate 160 so as to seal the photovoltaic cell 120 and the moisture absorbing layer 140 therein. More specifically, the sealant 150 is exemplified by disposing in a margin area of the front substrate 110 outside the photovoltaic cell 120 , the encapsulant 130 and the moisture absorbing layer 140 . In this manner, the sealant 150 completely seals the photovoltaic panel 100 and forms an enclosed space 100 a with the front substrate 110 and the back substrate 160 . The photovoltaic cell 120 and the moisture absorbing layer 140 are situated in the enclosed space 100 a to be protected from moisture and/or pollutant intrusion.
[0031] In the photovoltaic panel 100 as shown in FIG. 1 , the materials of the encapsulant 130 and the sealant 150 can be selected in accordance with the practical production needs. The exemplary materials for the encapsulant 130 includes, for example, commercially obtainable DuPont™ Elvax® ethyl vinyl acetate (EVA) resins, commercially obtainable DuPont™ PV5200 series encapsulant sheets, and commercially obtainable DuPont™ PV5300 series encapsulant sheets. The exemplary materials for the sealant 150 includes, for example, polyisobutylene (PIB), butyl rubber, VAMAC™, ethylene acrylic elastomers, Hypalon™, and chlorosulfonated polyethylene. The above mentioned materials are for exemplifications only, and are not intended to limit the scope of the disclosure.
[0032] In the present embodiment of FIG. 1 , the encapsulant 130 is exemplified is by disposing between the photovoltaic cell 120 and the moisture absorbing layer 140 , yet the disposition of the encapsulant 130 it is not limited thereto. FIG. 2 is a cross-sectional view of a photovoltaic panel according to another embodiment of the disclosure. The photovoltaic panel 200 , including the front substrate 210 , the photovoltaic cell 220 , the encapsulant 230 , the moisture absorbing layer 240 , the sealant 250 , and the back substrate 260 , differs from the photovoltaic panel 100 of FIG. 1 in that the encapsulant 230 is disposed between the moisture absorbing layer 240 and the back substrate 260 to encapsulate the photovoltaic cell 220 . Any other appropriate dispositions of the encapsulant to fully cover the photovoltaic cell can be used in the photovoltaic panel.
[0033] As shown in FIG. 1 , the encapsulant 130 and the moisture absorbing layer 140 are illustrated as two different layers, so are the encapsulant 230 and the moisture absorbing layer 240 depicted in FIG. 2 . However, in another embodiment, the two separate layers can be combined into one layer.
[0034] FIG. 3 is a cross-sectional view of a photovoltaic panel according to a further embodiment of the disclosure. The photovoltaic panel 300 includes a front substrate 310 , a photovoltaic cell 320 , a moisture absorbing layer 340 , a sealant 350 and a back substrate 360 . The photovoltaic cell 320 is disposed on the front substrate 310 , and the moisture absorbing layer 340 covers the photovoltaic cell 320 . The back substrate 360 is parallel to the front substrate 310 , and the photovoltaic cell 320 and the moisture absorbing layer 340 are situated between the front substrate 310 and the back substrate 360 . The moisture absorbing layer 340 covers the photovoltaic cell 320 , more specifically, fully overlays a top surface 321 of the photovoltaic cell 320 .
[0035] The moisture absorbing layer 340 of the present embodiment includes an encapsulant and a micro-porous desiccant blended in the encapsulant. The micro-porous desiccant is structured as a molecular sieve and includes zeolite, which is similar to that included in the moisture absorbing layer 140 of the previously described photovoltaic panel 100 (as depicted in FIG. 1 ). The micro-porous desiccant is blended in the encapsulant by mixing a predetermined proportion of zeolite nanoparticles into the encapsulant raw material, e.g. EVA resin, during the formation of the EVA film. The micro-porous desiccant serves as a molecular sieve to trap moisture and pollutant gases. The pore size of the micro-porous desiccant ranges from about 0.3 nm to about 1 nm. On the other hand, the exemplary materials for the encapsulant includes, for example, commercially obtainable DuPont™ Elvax® ethyl vinyl acetate (EVA) resins, commercially obtainable DuPont™ PV5200 series encapsulant sheets, and commercially obtainable DuPont™ PV5300 series encapsulant sheets.
[0036] The photovoltaic panel 300 uses one layer of encapsulant with micro-porous desiccant blended therein, to encapsulate the photovoltaic cell 320 and to trap moisture at the same time, thus the structure of the photovoltaic panel 300 is further simplified and the cost is reduced accordingly.
[0037] The detailed description now directs to a method of manufacturing a photovoltaic panel. In order to clearly show the characteristics of the disclosure, the above mentioned photovoltaic panel 100 is taken as an example here with reference to FIG. 1 and FIG. 4 . FIG. 4 is a flow chart of a method of manufacturing a photovoltaic panel according to one embodiment of the disclosure.
[0038] Of the method of manufacturing the photovoltaic panel 100 , the photovoltaic cell 120 is formed on the front substrate 110 as shown in step S 1 . The photovoltaic cell 120 may be deposited by chemical vapor deposition (CVD), physical vapor deposition (PVD), sputtering, or any other methods known to a person who is skilled in the art.
[0039] In step S 2 , the moisture absorbing layer 140 is applied to cover the photovoltaic cell 120 . Exemplarily, the step S 2 is performed by laminating a film of the micro-porous desiccant, zeolite for example, onto the photovoltaic cell 120 . For example, a getter composite film containing zeolite nanoparticles can be laminated onto the photovoltaic cell 120 .
[0040] Optionally, a step of encapsulating the photovoltaic cell 120 by the encapsulant 130 can be performed prior to laminating the film. Alternatively, the step of encapsulating the photovoltaic cell 120 is performed after step S 2 in another embodiment. The sequence of the two steps is not limited here in the disclosure, as long as the photovoltaic cell 120 can be encapsulated by the encapsulant 130 and covered by the moisture absorbing layer 140 .
[0041] In another embodiment, the step S 2 and the step of encapsulating the photovoltaic cell 120 can be combined into one step by laminating a film of the encapsulant with the micro-porous desiccant blended therein. The photovoltaic cell 120 is therefore protected from the intrusion of moisture and pollutants by the laminated film. The micro-porous desiccant can be exemplified by zeolite, and the encapsulant can be exemplified by EVA. The micro-porous desiccant is formed by mixing a predetermined proportion of zeolite nanoparticles into the encapsulant raw material, e.g. EVA resin, during the formation of the EVA film. Then, the encapsulant is laminated over the photovoltaic cell 120 .
[0042] Then, the method moves on to step S 3 , in which the sealant 150 is applied at or near the edges of the front substrate 110 . In one embodiment, the sealant 150 is applied to a marginal area of the front substrate 110 outside the photovoltaic cell 120 , the encapsulant 130 and the moisture absorbing layer 140 . More specifically, the sealant 150 is disposed completely surrounding the photovoltaic cell 120 , the encapsulant 130 and the moisture absorbing layer 140 .
[0043] Finally, in step S 4 , the back substrate 160 is secured onto the front substrate 110 . As a result, the photovoltaic cell 120 , the moisture absorbing layer 140 and the sealant 150 are situated within a space formed by the front substrate 110 , the back substrate 160 and the sealant 150 . Specifically, the sealant 150 , the front substrate 110 and the back substrate 160 form an enclosed space 100 a , and the photovoltaic cell 120 and the moisture absorbing layer 140 are enclosed therein or are situated in the enclosed space 100 a.
[0044] After completion of step S 4 , the photovoltaic panel 100 is thereby completed. By the protection of the sealant 150 and the moisture absorbing layer 140 , the moisture intrusion to the photovoltaic cell 120 is prevented, as well as the delamination and corrosion of materials in the photovoltaic panel 100 .
[0045] In the above-described photovoltaic panel and method of manufacturing the same, the moisture intrusion from the back substrate of the panel can be blocked by the moisture absorbing layer, so as to prevent the delaminations and corrosions of materials and to prolong the life span of the photovoltaic panel accordingly. Furthermore, the power degradation of the photovoltaic cell is prevented, increasing the reliability and the performance of the photovoltaic panel. Moreover, the moisture absorbing layer includes zeolite or encapsulant with zeolite blended therein, making the moisture absorbing layer cheap and easy to obtain.
[0046] It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present disclosure without departing from the scope or spirit of the disclosure. In view of the foregoing, it is intended that the present disclosure cover modifications and variations of this disclosure provided they fall within the scope of the following claims.
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Disclosed herein are a photovoltaic panel and a method of manufacturing the same. The panel includes a front substrate, a photovoltaic cell on the front substrate, a moisture absorbing layer covering the cell to protect the cell from moisture intrusion, a back substrate on the moisture absorbing layer, and a sealant between the substrates. The method includes the steps of forming the photovoltaic cell on the front substrate, applying the moisture absorbing layer covering the cell, applying the sealant at or near the edges of the front substrate, and securing the back substrate to the front substrate.
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BACKGROUND OF THE INVENTION
The invention relates to a system and components thereof to control the covering of a core element with strands of reinforcing material by rotary braiding on tandem or adjacent machines.
As an operating unit, a rotary braiding machine suitable for being controlled according to the invention is now known, ad is described in the prior art.
The following United States Patents, now owned by the inventor's assignee, Karg Corporation, Tallmadge, Ohio U.S.A., disclose and claim various components of a rotary braiding machine suitable for control according to the invention: U.S. Pat. Nos. 3,756,117; 3,756,523: 3,756,533; and 3,757,904, each Sept./1973; and, 3,802,643, April/1974.
A machine suitable for being controlled according to the invention will have a rotating braiding mechanism and a revolving capstan drum for moving a flexible core element. The braiding mechanism and the capstan drum are powered by a variable speed motor.
The braiding mechanism includes a spool holder drive mechanism for actuating relative movement of a set of outer spools and a set of inner spools along circular paths in opposite directions. A material strand from each spool is let off toward the "work center" for braiding as to each other and around a moving flexible core element introduced coaxially of the braiding mechanism. The capstan includes a drive mechanism for actuating a revolving movement of a capstan drum. Multiple loops of a composite article, the core element with a covering of braided strands thereon, are wrapped around the drum in frictional engagement therewith.
In all known machine performed operations for covering a core element with a layer of braided strands, the "braid angle" or pitch of the braided strands will be established by the rate or speed of lineal progression during the circuar or wrapping movement of strands from the spools around the core element.
In the rotary braiding machines controlled according to the invention, the braid angle is a resultant of three factors: (1 ) outer diameter of the core element; (2) rate of lineal movement of the core element when passing through the "work center"; and, (3) rate of wrapping movement of the strands around the core element when in the "work center."
For any given dimensional factor (1), the greater the difference between the movement of factor (2) and the movement of factor (3), the lower or steeper the resultant braid angle. Conversely, for a given factor (1), a smaller difference between the movements of factors (2) and (3) will produce a product with a higher or flatter braid angle.
Control of tandem braiding machines according to the invention contemplates that each machine will have as a discrete operational component thereof an adjustable proportional control means to determine a specific braid angle for the strand covering on the core element. Each proportional control means will synchronize the revolving movement of the capstan drum (providing a lineal movement of a core element) and the circular movement of the sets of outer and inner spools (providing a wrapping movement of the strands). It is preferred that the power input to each proportional control means be from a single variable speed drive motor mounted on each machine frame.
The products which will be manufactured according to the invention are known, conventional, many and varied. The products may be plastic or rubber hose, cable, cord, line, or even rope. For this disclosure, the product shown is a very long length of rubber tubing reinforced by double-braided strands and intended for an end use, in suitable lengths and with suitable end fittings or couplings, in the transmission of hydraulic fluids under high pressure. Such a product is generically called "industrial hose."
Before now, there have been several types of techniques for continuous manufacture of industrial hose products disclosed in the prior art.
Commercial manufacturers of industrial hose products have long known of the company W & M Ostermann, Wuppertal-Barmen, Germany. The "Ostermann" equipment has included a horizontally operating machine with two rotating braiding mechanisms, "first pass" and "second pass," arranged symmetrically around a steel pole or rigid mandrel and having a caterpillar haul-off for the mandrel and multiple-braided product. U.S. Pat. No. 3,183,583, Ostermann, May/1965, discloses a horizontal machine used with two winding heads but otherwise structurally equivalent to the known "Ostermann" braiding machine.
A continuous process for the manufacture of reinforced hose using horizontally arranged tandem units for applying reinforcement "in the form of knitted, woven, braided or lapped textile yarns or the like between extruded elastomeric inner and outer layers" is disclosed in U.S. Pat. No. 3,586,558, Galloway et al, June/1971.
It has also been possible to use the "Karg" rotary braiding machines for the sequential manufacture of industrial hose products. An inner layer of braided strands is applied to a flexible core element during a "first pass" through a machine. The intermediate product is led from the capstan to suitable storage reels. After a suitable quantity of the intermediate product has been accumulated, the storage reels are positioned as supply reels and the outer braided strand layer is applied during a "second pass" through a machine.
It has now been found that an operable system to control the continuous process covering of a flexible core with multiple-braided strands of reinforcing material need not be complex, may be relatively inexpensive to install, operate and maintain, and will satisfactorily perform to produce large quantities of products with different braid angle and design specifications at a lowered direct labor cost with a reasonable capital investement.
SUMMARY OF THE INVENTION
The object of the invention is to provide an improved system and components thereof to control the covering of a core element with strands of reinforcing material by rotary braiding on tandem or adjacent machines.
It is further object of the invention to provide an improved system and components thereof for controlling the operating speeds of at least two machines, located in tandem or an adjacent arrangement, for covering a moving flexible core element with multiple-layers of reinforcing strands in a process of continuous manufacture.
The present invention was specifically conceived to control the operation of tandem machines having a rotating braiding mechanism and a revolving capstan drum for moving a flexible core element. A specific object is to provide for these machines a control system which is not complex, which is relatively inexpensive to install, operate and maintain, and which will satisfactorily perform to produce large quantities of products with different braid angle and design specifications.
These and other objects of the invention, and further advantages thereof, will be apparent in view of the description of the components thereof and the various operating modes as set forth below.
In general, the invention relates to controlling the operating speeds of tandem machines for covering a moving flexible core element with multiple-layers of reinforcing strands in a process of continuous manufacture.
According to the invention, an operator of the machines is provided with components to establish and define a chorded festoon having vertically aligned upper and lower parameters and extending laterally between first and second machines. A "festoon" is a gravity influenced hanging loop of a product being moved from a first point to a second point during a manufacturing operation. A "chorded festoon" is a mechanically influenced loop of the core element with a first layer of reinforcing strands thereon during lateral movement from a first machine to a second machine. As used herein, the phrases "parameters of" or "vertically aligned upper and lower parameters of" a chorded festoon shall mean two sets or pairs of imaginary or projected linear and intersecting chords; an upper limit and a lower limit. Each pair of projected chords originate at a common point on the first machine and terminate at a common point relative to the second machine. Each pair of projected chords will intersect in an area substantially midway between the first and second machines. The width or height of the chorded festoon will be greatest at these two, upper and lower, projected intersections.
The invention further provides the operator with components to determine and define a vertically oriented zone of operational tolerance within the upper and lower parameters of the chorded festoon and in an area substantially midway between the first and second machines; between the intersections of the upper and lower projected chords. The width or height of the zone of operational tolerance will be dictated by or take into consideration the braid angle and design specification of the product being manufactured.
The invention further provides the operator with components for continuously monitoring the position of a core element with a first layer of reinforcing strands thereon, during lateral movement from the first machine toward the second machine, at any point within the parameters of or between the ends of the chorded festoon.
Still further, the invention provides the operator with components for detecting any position of the laterally moving core element which is changing or has changed within the zone of operational tolerance.
Finally, the invention provides components which will function automatically, without operator intervention, to regulate the operating speed of one machine to correspond with the operating speed of the other machine to return the laterally moving core element from a detected changed position to another position, a preselected or "normal" position, within the zone operational tolerance.
Also the invention provides the operator with components which will also function automatically to stop or halt the operation of both machines when any position of the moving core element is changing to exceed, be beyond, or be outside of either parameter of the chorded festoon.
The disclosed embodiment relates to the control of tandem braiding machines to cover a flexible core element with layers of braided reinforcing strands during successive passes. Each machine has a powered rotating braiding mechanism and a powered capstan drum for moving the core element through the braiding mechanism. Practice of the invention of this embodiment requires powering the braiding mechanism and the capstan drum of each machine from single variable speed drive motor and proportionally controlling the power output from each drive motor to determine a specific braid angle for each layer of reinforcing strands.
The disclosed embodiment relates specifically to the control of tandem rotary braiding machines for continuous manufacture of a product with design specifications requiring that first and second strand layers have a different braid angle. If the first machine covers the core element with strands having a relatively flat braid angle and the second machine covers the flat braid with strands having a relatively steep braid angle, the system regulates the operating speed of the second machine drive motor while maintaining a constant operating speed for the first machine drive motor. If the first machine covering is to have a steep braid angle and the second machine covering is to have a flat braid angle, the operating speed of the first machine drive motor is regulated and the operating speed of the second machine drive motor is maintained constant. In either mode, regulation of one drive motor will return the moving core element to the preselected position within the zone of operational tolerance.
THE DRAWINGS
FIG. 1 is an elevational view of tandem braiding machines to cover a flexible core element with layers of braided reinforcing strands during successive passes through the braiding mechanisms of the machines and a control system and components thereof according to the invention;
FIG. 2 is a plan view of a rotary braiding machine, partially broken away, showing sets of outer and inner spools of a braiding mechanism and a revolving capstan drum for moving a flexible core element;
FIG. 3 is a rear elevation of a rotary braiding machine, taken substantially as indicated on line 3--3 of FIG. 2, including schematic details of a spool holder drive mechanism and a capstan drive mechanism powered by a single variable speed drive motor;
FIG. 4 is a perspective view of braiding machine components including an adjustable proportional control means, with a power input from a single drive motor, to synchronize the revolving movement of a capstan drum and the circular movement of the spool holder drive mechanism to determine a specific braid angle for the strand covering on a flexible core element;
FIG. 5 is a schematic elevation showing the parameters of a chorded festoon extending laterally between first and second rotary braiding machines;
FIG. 6 is an exploded perspective view of a speed controller system component to be positioned substantially midway between the first and second rotary braiding machines;
FIG. 7 is a plan view of an industrial hose product, broken away to show a flexible core element, an inner layer of strands having a relatively flat braid angle and an outer layer of strands having a relatively steep braid angle;
FIG. 8 is a schematic view of a speed controller component according to FIG. 6 being used in an operating mode wherein the first machine covers a moving core element with a layer of strands having a relatively flat braid angle and the second machine covers the flat braid with a layer of strands having a relatively steep braid angle--a first pass master-second pass slave, mode;
FIG. 9 is a schematic view of a speed controller component being used in an operating mode wherein the first machine covers a moving core element with a layer of strands having a relatively steep braid angle and the second machine covers the steep braid with a layer of strand having a relatively flat braid angle--a first pass slave-second pass master, mode;
FIG. 10 is a plan view of the panel of a master control console;
FIG. 10A is a plan view of the panel of a control box on a rotary braiding machine; and,
FIGS. 11A, 11B and 11C are fragmentary wiring diagrams to be considered in conjunction with each other and the control panels of FIGS. 10 and 10A, as well as individually.
DETAILED DESCRIPTION OF THE INVENTION
A system according to the invention will be referred to generally by the numeral 20. The various components of a system 20, in the disclosed embodiment, will be identified by specific reference numerals.
As shown, the system 20 and components thereof control the covering of a core element 21 with strands of reinforcing material 22 by rotary braiding on tandem or adjacent machines; a first machine 23 and a second machine 24.
A representative or typical product which could be manufactured in a continuous process according to the invention, a product generically called "industrial hose," is disclosed in FIG. 7. The product shown, referred to generally by the numeral 25, has a flexible core element 21 serving during end use as a conduit for transmission of hydraulic fluids under high pressure. The core element 21 is reinforced, for end use, by double-braided strands 22. The inner layer 26 of strands 22 has a relatively flat braid angle (α 1 ). The outer layer 27 of strands 22 has a relatively steep braid angle (α 2 ).
As used herein, the phrase "core element 21" shall mean the coaxial structure around which the strands 22 are laid. The core element 21 is called "flexible" to distinguish from the steel pole or rigid mandrel of the prior art "Ostermann" equipment.
As used herein, the phrase "strands of reinforcing material 22" shall mean any small or fine diameter material capable of being stored on spools and intended for tensioned interlacing, weaving, spiralling or braiding as to each other or around a core member. The strands 22 may be a synthetic or natural fibre, or thread, or of metallic origin. Or, the strand layers 26 and 27 may have different compositions.
Referring to FIG. 1, the operating environment for the system 20 and the tandem rotary braiding machines 23 and 24 requires an area of factory floor 28 adequate for the placement of conventional core element supply reels 29 and product take-up reels 30. The machine 23 and 24 may be placed "in-line," as shown; or at angles one to the other, so long as there is space in between for components of the system 20.
Mechanical and operational features of a machine 23 (or 24) are shown in FIGS. 2 and 3. The braiding machine 23 (or 24) has a structural frame with a support member 31 for mounting on the floor 28. A machine 23 (or 24) includes a braiding mechanism indicated generally at 32, a variable speed drive motor 34, a contol box 35 (also, see FIG. 10A), a capstan support housing 36, a revolving capstan drum indicated generally at 37, an interior braiding point retainer 38, and an exterior braiding point retainer 39. The "work center" of the machine 23 (or 24) is in the area between the retainers 38 and 39.
Referring to FIG. 2, the braiding mechanism 32 includes a spool holder drive mechanism (not shown in detail) which actuates relative movement of a set of outer spools 40A and a set of inner spools 40B along circular paths in opposite directions. A reinforcing strand 22 from each spool 40A and 40B is let off toward the "work center" for braiding as to each other and around the moving core element 21 introduced coaxially of the braiding mechanism 32.
Each machine 23 or 24 preferably will have a proportional control means, referred to generally by the numeral 41, to synchronize the revolving movement of the capstan drum 37 (providing a lineal movement of the core element 21) and the circular movement of the sets of outer and inner spools 40A and 40B (providing a wrapping movement of the strands 22). The power input to a proportional control means 41 is from the drive motor 34 mounted on a machine frame 31.
Referring to FIG. 4, the drive motor 34 is coupled to a right angle gear box 42 with a shaft 43 mounting a cog pulley 44. The larger diameter pulley 44 is connected by a cog belt 45 to a smaller diameter cog pulley 46. The cog pulley 46 is carried on the power input shaft 47 of an epicyclic gear unit 48. A spool holder drive mechanism will include a drive gear 49 meshing with a smaller gear 51 carried on the end of a power shaft 52 originating in the gear unit 48.
(Elements 49, 51 and 52, just described, are identified by like numerals in the description and drawings of U.S. Pat. No. 3,756,117, DeYoung, September/1973, for a Spool Holder Drive Mechanism.)
The drive mechanism for the capstan drum 37 includes a power shaft 53 originating in the gear unit 48 and terminating in a right angle gear box 54 having an output shaft 55. The output shaft 55 carries a primary gear 56 which continuously meshes with a secondary gear 57. (Further reference to the function of gears 56 and 57 will follow.) Gear 57 is carried on a sprocket shaft 58 engaging a drive chain 59 extending upwardly and around a sprocket 60. The sprocket 60 is carried by a sprocket shaft 61 journaled in the capstan housing (36). Sprocket shaft 61 engages a drive chain 62 extending laterally and around a drive sprocket 63 mounted on a drive shaft 64 carrying the capstan drum 37.
A proportional control means 41, including elements 42-49 and 51-64 as described, will generally function to determine a specific braid angle for a covering of strands 22 on a core element 21 at any operating speed of the drive motor 34, from minimum speed to maximum speed. The primary and secondary gears, 56 and 57, in the power train of the capstan drive mechanism are specifically intended to readily provide for a change in braid angle design. An increase in the effective diameter of gear 56 relative to the diameter of gear 57 will increase the rate of lineal movement of the core element 21 relative to the rate of wrapping movement of the strands 22 around the core element 21 and the product 25 will have strand layers 25 (or 26) with a steeper (lower) braid angle. A relative decrease in the size ratio of gear 56 to gear 57 will provide a product 25 with strand layers 25 (or 26) having a flatter (higher) braid angle.
Referring to FIG. 3, a machine 23 or 24 may use a roller 65 to maintain multiple loops of the core element 21 in symmetric frictional engagement with the capstan drum 37.
Effective control by the system 20 of the operating speeds of machines 23 and 24 to manufacture a product 25 is made possible by a concept of the invention whereby the parameters of a chorded festoon extend laterally between the machines. This concept of chorded festoon control of a moving flexible core element 21 during covering with layers of strands 22 is best shown in FIG. 5.
The chorded festoon, referred to generally by the numeral 70, comprises two sets or pairs of imaginary or projected linear and intersection chords. The upper parameter, or upper limit, comprises chain lines 71L and 71R. The lower parameter, or lower limit, comprises chain lines 72L and 72R. The linear factors of the lines 71 and 72 are to be regarded and considered as vertically aligned. Chords 71L and 72L originate at a point 73 on the surface of the periphery of a revolving capstan drum 37. Chords 71R and 72R terminate at a point 74 on the surface of a guide roller 75.
Referring also to FIG. 1, a guide roller 75 is a freely rotating idler roll with a shaft 76 carried by a base or stanchion 77 mounted on the floor 28 beneath machine 24. The base 77 is positioned so as to define the exit end of the chorded festoon 70 and also to direct a core element 21 with a strand layer 26 thereon coaxially into the second pass braiding mechanism 32.
Referring again to FIG. 5, each pair of projected chords, 71L and 71R and 72L and 72R, do intersect in an area substantially midway between the machines 23 and 24. The width or height of the chorded festoon 70, as indicated by the slanted lines, is greatest at these two, upper and lower, projected intersections of chords 71L and 71R and 72L and 72R. The chorded festoon 70 is achieved by the use of a speed controller unit, referred to generally by the numeral 80.
The components of a speed controller unit 80 according to the invention are best shown in FIG. 6. A base member or plate 81 is adapted for mounting on the floor 28 substantially midway between the machines 23 and 24. The base member 81 carries a vertically oriented stanchion 82 extending upwardly to a suitable height. The stanchion 82 has a transverse bore 83 therethrough to receive the horizontally oriented and freely rotating control shaft 84 of a core element position indicator potentiometer, referred to generally by the numeral 85 (DCR1), secured to the front face of the stanchion 82.
The end of the control shaft 84 extending through the stanchion 82 carries the base of a core element position monitoring and change detecting elongated wand or slender projecting rod 86. The arcuate movement path of the wand 86 around the axis provided by shaft 84 has a downward "at rest" position, as provided by an abutment stop element 87 on the rear face of the stanchion 82.
The arcuately moving projecting end of the wand 86 mounts a core element position monitoring means or roller 88. A roller 88 is mounted to freely rotate, with minimal frictional drag, when the periphery 89 thereof is in contact with a laterally moving core element 21 with a strand layer 26 thereon. A roller 88 also has a mass or weight such as to mechanically influence the laterally moving core element to form a chorded festoon.
The electrical functions of the potentiometer 85 of the speed controller unit 80 are described in detail below with reference to FIG. 11B. Referring to FIG. 6 (upper left hand corner), the shaft 84 carries a wiper arm 90 in movable engagement with the incrementally spaced contact points of the resistance circuitry 91. The shaft 84 also carries a cam lug 92 for selective actuation of either of a pair of normally closed limit switches 93 and 94; upper and lower limit (DSHLS and DSLLS).
The electrical components of a system 20 include a master control console 99 positioned on the floor 28 so that the operator can see both machines, 23 and 24, and the current physical position of the wand 86 and roller 88 of the speed controller unit 80.
The system 20 provides the operator of tandem rotary braiding machines 23 and 24 with a master control console 99 having a panel 100, as shown by FIG. 10. The left hand portion of the master control panel 100 may have: a potentiometer 101 for determining the operating speed of the drive motor of the first machine 23; a "run" button 102 for starting machine 23; a "jog" button 103 for selective use (as during leading of a core element 21 through the braiding mechanism and wrapping around the capstan drum 37 of machine 23); and a "stop" button 104 for machine 23.
Similarly, the right hand portion of the master control panel 100 will have: a potentiometer 105 for determining the operating speed of the drive motor for the second machine 24; a "run" button 106 for machine 24; a "jog" button 107; and, a "stop" button 108 for machine 24.
The midportion of the master control panel 100 has a three function switch 109. The left hand function or "first pass" is used when machine 23 is "master" and machine 24 is "slave"; when the braid angle of strand layer 26 is flatter than the braid angle of strand layer 27. The right hand function or "second pass" is used when machine 24 is "master" and machine 23 is "slave"; when the braid angle of strand layer 27 is flatter than the braid angle of strand layer 26. The middle function of switch 109 is used when the operator is individually operating machine 23 and 24.
Below switch 109, the master control panel has: an indicating light 110, "controller tripped" (showing the speed controller unit 80 as inoperative); a button 111 "controller reset" (to reactivate unit 80); a "master run" button 112 for starting the drive motors of both machines, 23 and 24; a "master jog" button 113 controlling both machines; and a "master emergency stop" button 114 for everything being controlled by the system 20.
The system 20 also permits the operator to individually operate either machine 23 or 24 from the panel 115 of a control box 35. As shown by FIG. 10A, the machine control panel 115 has: a "run" button 116; a "jog" button 117; and, a "stop button" 118.
The elements of the circuitry in the system 20 controlled from the master control console 99 are shown by the wiring diagrams of FIGS. 11A, 11B and 11C, which are to be considered in conjunction with each other as well as individually.
FIG. 11A shows electrical components of the system 20 which could be physically installed in the control box 35 for or on the first machine 23. FIG. 11C shows electrical components of the system 20 which could be physically installed in the control box 35 for or on the second machine 24. The components in FIGS. 11A and 11C are suitably interconnected with the electrical components in FIG. 11B, preferably installed on the master console 99 beneath the control panel 100. FIG. 11B also shows the operative relation of the mechanical and electrical components of the speed controller unit 80 to the electrical components of the system 20.
Referring to FIG. 11A, power is supplied to the first machine 23 by manual closing of a master power switch DISC-A. Power is thereby applied to the motor control circuit MC-23 and also to a transformer T1-A. The transformer T1-A provides 110 V current on lines 2-A and 3-A, and 6.3 V current on lines 4-A and 5-A. The 6.3 V current energizes relay R6-A through contacts R7-A and R5A-A (and, also SW8B on FIG. 11B). The 6.3 V current also closes contacts R6A-A and R6B-A forming a part of a holding circuit for operation of the first machine drive motor 34.
Referring to FIG. 11C, power is supplied to the second machine 24 by manual closing of a master power switch DISC-C. Power is thereby applied to the motor control circuit MC-24 and also to a transformer T1-C. The transformer T1-C provides 110 V current on lines 2-C and 3-C, and 6.3 V current on lines 4-C and 5-C. The 6.3 V current energizes relay R6-C through contacts R7A-C and R5A-C (and, also SW9B on FIG. 11B). The 6.3 V current also closes contacts R6A-C and R6B-C forming a part of a holding circuit for operation of the second machine drive motor 34.
Individual Operation of Each Machine, 23 or 24
Referring to FIGS. 10, 11A and 11B, the operator may start the first machine 23 by momentarily depressing the "run" button 102 (SW4) to close contact SW4A. The closing of contact SW4A provides 110 V current from line 3-A to relays R2-A and R5-A through contacts R4A-A, SW6A, SW10A, SW4A and R4B-A. The other side of relays R2-A and R5-A are connected to line 2-A. Energizing relay R2-A opens contact R2A-A, which removes power from a suitably located safety or "motor off" indicator light L1-23. Energizing relay R5-A opens contact R5A-A and closes contacts R5B-A and R5C-A. The closing of contact R5B-A actuates the motor control circuit MC-23 to start operation of the first machine drive motor 34 (M). The motor 34 will drive the gear box 42 at a speed determined by the adjustable setting of potentiometer RC1-A through relay contacts R3A-A, R3B-A, and R3C-A.
The operator may stop the first machine 23 by momentarily depressing the "stop" button 104 (SW6) and thereby de-energizing relay R5-A opening contact R5B-A in the motor control circuit, and opening contact R5C-A forming a part of the run holding circuit for operating the drive motor 34.
A machine 23 will preferably have a safety circuit for indicating when a spool 40A or 40B has been depleted of a reinforcing strand 22. When such a safety circuit is tripped, a relay R7-A is energized opening contact R7A-A to de-energize relay R6-A. A de-energization of relay R6-A opens contact R6B-A in the run holding circuit and de-energizes relay R5-A.
The operator may jog the first machine 23 by depressing the "jog" button 103 (SW8) and thereby providing current for relays R2-A and R5-A through contacts R4A-A, SW6A, SW10A, and SW8A. When button 103 is continually depressed, contact SW8B is opened removing power from relay R6-A which opens contact R6B-A in the run holding circuit. The first machine 23 will run only so long as button 103 (SW8) is depressed.
Referring to FIGS. 10, 11B and 11C, the operator may start the second machine 24 by momentarily depressing the "run" button 106 (SW5) to close contact SW5A. The closing of contact SW5A provides 110 V current from line 3-C to relays R2-C and R5-C through contacts R4A-C, SW7A, SW10B, SW5A, and R4B-C. The other side of relays R2-C and R5-C are connected to line 2-C. Energizing relay R2-C opens contact R2A-C, which removes power from a suitably located safety or "motor off" indicator light L1-24. Energizing relay R5-C opens contact R5A-C and closes contacts R5B-C and R5C-C. The closing of contact R5B-C actuates the motor control circuit MC-24 to start operation of the second machine drive motor 34 (M). The motor 34 will drive the gear box 42 at a speed determined by the adjustable setting of potentiometer RC1-C through relay contacts R3A-C, R3B-C, and R3C-C.
The operator may stop the second machine 24 by momentarily depressing the "stop" button 108 (SW7) and thereby de-energizing relay R5-C opening contact R5B-C in the motor control circuit, and opening contact R5C-C forming a part of the run holding circuit for operating the drive motor 34.
A machine 24 will preferably have a safety circuit for indicating when a spool 40A or 40B has been depleted of a reinforcing strand 22. When such a safety circuit is tripped, a relay R7-C is energized opening contact R7A-C to de-energize relay R6-C. A de-energization of relay R6-C opens contact R6B-C in the run holding circuit and de-energizes relay R5-C.
The operator may jog the second machine 24 by depressing the "jog" button 107 (SW9) and thereby providing current for relays R2-C and R5-C through contacts R4A-C, SW7A, SW10B, and SW9A. When button 107 is continually depressed, contact SW9B is opened removing power from relay R6-C which opens contact R6B-C in the run holding circuit. The second machine will run only so long as the button 107 (SW9) is depressed.
First Tandem Mode of Operation When Machine 23 is "Master" and Machine 24 is "Slave"
This mode of operation is preferably used when the first machine 23 covers the moving core element with a layer of strands 26 having a relatively flat braid angle and the second machine 24 covers the flat braid with a layer of strands 27 having a relatively steep braid angle.
Referring to FIGS. 11A and 11C, power is supplied to both machines, 23 and 24, by manual closing of the master power switches, DISC-A and DISC-C. Power is thereby applied to the motor control circuits MC-23 and MC-24 and also to transformers T1-A and T1-C. The transformer T1-A provides 110 V current on lines 2-A and 3-A, and 6.3 V current on lines 4-A and 5-A. The transformer T1-C provides 110 V current on lines 2-C and 3-C, and 6.3 V current on lines 4-C and 5-C.
Referring also to FIGS. 10 and 11B, with switch 109 (SW1) in the left hand position for "first pass," contacts SW1B, SW1C and SW1D will be closed. The 110 V current from line 3-A provides power for relays R3-A and R4-A through contact SW1B. The 110 V current from line 3-C provides power for relay R1-C through contact SW1C, and power for relays R3-C and R4-C through contact SW1D. When relay R3-A is energized, contacts R3A-A, R3B-A and R3C-A are opened to isolate the potentiometer RC1-A, for the first machine 23, from the motor control circuit MC-23. Also, when relay R3-A is energized, contacts R3D-A, R3E-A, and R3F-A are closed providing a circuit path through closed contacts R1D-A, R1E-A and R1F-A for the potentiometer 101 (RC2A) to the motor control circuit MC-23. When relays R1-C and R3-C are energized, contacts R3A-C, R3B-C, R3C-C, R1D-C, R1E-C and R1F-C are opened to isolate both the potentiometer RC1-C, for the second machine 24, and the potentiometer 105 (RC2C) from the motor control circuit MC-24. Also, when relays R1-C and R3-C are energized, contacts R1A-C, R1B-C, R1C-C, R3D-C, R3E-C, and R3F-C are closed providing a circuit path for the potentiometer 85 (DCR1) to the motor control circuit MC-24. The contacts R1A-A,R1B-A, and R1C-A remain open during operation of the machines, 23 and 24, in this mode. The system 20 will now be ready to enable the operator to select the base operating speed for the first machine 23.
The base operating speed of a rotary braiding machine is a variable factor; a value which is preferably chosen in a range between ten percent (10%) and ninety percent (90%) of the maximum speed as limited by the circular movement of the braiding mechanism 32. The choice of a particular operating speed for a machine 23 or 24 is dictated or determined by the physical properties of the product 25; more specifically, the characteristics of a core element 21 and strands 22.
For example, a core element 21 which is inherently subject to a disproportionate elongation under the tension of a revolving capstan drum 37 will generally be braided at a slower operating speed. Conversely, a relatively non-extensible core element 21 should enable the operator to choose a faster operating speed. Also, a metallic strand 22, having inherent rigidity, would generally be braided at a slower operating speed, as contrasted with a strand 22 of natural or synthetic fibre which could be braided at a faster operating speed. In any event, the system 20 enables the operator to choose an appropriate operating speed for moving the core element 21 to pass through the braiding mechanism 32 of the first machine 23 and to pass through the braiding mechanism 32 of the second machine 24 by concurrent operation of the drive motors 34 of each machine.
FIG. 8 is intended to schematically show operating variables available to the operator in the first pass master-second pass slave mode. The input shaft 84 to the potentiometer 85 (DCR1) is intended to have a 90° total angular travel. At either side, an arc segment of 9° has been dedicated for use in stopping the operation of the drive motors 34 for each machine, 23 and 24. It has been found that an arc segment of 72° for movement of the wand 86 and roller 88 will enable the operator to effectively and accurately control the covering of a core element 21 at any operating speed chosen in the 10% to 90% range.
Referring again to FIGS. 10, 11A and 11B, the operator manually sets the potentiometer 101 (RC2A) to determine the base operating speed of the drive motor of the first machine 23. The roller 88 of the speed controller unit 80 is positioned so that the normally closed limit switches 93 and 94 (DSHLS and DSLLS, respectively) remain in a condition to energize the relay DSR1. The operator starts the machines 23 and 24 in tandem operation by momentarily depressing the "master run" button 112 (SW3).
The closing of contact SW3A provides 110 V current from line 3-A to relays R2-A and R5-A through contacts DSR1B, SW7B, SW6A, SW10A, SW3A, and R4D-A. Energizing relay R2-A opens contact R2A-A, which removes power from a suitably located safety or "motor off" indicator light L1-23. Energizing relay R5-A opens contact R5A-A and closes contacts R5B-A and R5C-A. The closing of contact R5B-A actuates the motor control circuit MC-23 to start operation of the first machine drive motor 34. Relay R5-A is held in an energized condition through contacts DSR1B, SW7B, SW6A, SW10A, SW2B, R6B-A and R5C-A.
Simultaneously, the closing of contact SW3B provides 110 V current from line 3-C to relays R2-C and R5-C through contacts DSR1C, SW6B, SW7A, SW10B, SW3B, and R4D-C. Energizing relay R2-C opens contact R2A-C, which removes power from a suitably located safety or "motor off" indicator light LI-24. Energizing relay R5-C opens contact R5A-C and closes contacts R5B-C and R5C-C. The closing of contact R5B-C actuates the motor control circuit MC-24 to start operation of the second machine drive motor 34. Relay R5-C is held in an energized condition through contacts DSR1C, SW6B, SW7A, SW10B, SW2D, R6B-C and R5C-C.
In this mode, the operating speed and the power output of the drive motor for the first machine 23 is maintained constant, as determined by the operator setting of the potentiometer 101 (RC2A). The operating speed and the power output of the drive motor for the second machine 24 is automatically regulated by the potentiometer 85 of the speed controller unit 80.
Referring again to FIGS. 1, 5, 6 and 8 (and 9), the concurrent operation of the drive motors of each machine, 23 or 24, will move the core element 21 with a strand layer 26 laterally from machine 23 to machine 24. The weight of roller 88 of the speed controller unit 80 will mechanically influence the laterally moving core element to form a chorded festoon. The revolving roller 88 will also function to continuously monitor any position of the moving core element. The wand 86 carrying the roller 88 and connected to the potentiometer shaft 84 will detect any position of the laterally moving core element which is changing. Any rotation of the shaft 84, in either direction, will result in a movement of the potentiometer wiper arm 90 to vary the voltage output of the resistance circuitry 91.
Referring again to FIGS. 11B and 11C, the voltage output of the potentiometer 85 (DCR1) is transmitted to the motor control circuit MC-24. Any downward arcuate movement of the wand 86 and roller 88 will increase the operating speed of the second machine drive motor 34. Any upward arcuate movement of the wand 86 and roller 88 will decrease the operating speed of the second machine drive motor.
The system 20 further provides the operator with components which will function automatically to stop or halt the drive motors 34 of both machines, 23 and 24, when any position of the moving core element is changing to exceed the parameters of the chorded festoon. With reference to FIGS. 5 and 8, the normally closed limit switches 93 and 94, best shown in FIG. 6, are positioned to function at a selected point within a 9° arc segment. Switch 93 defines an upper limit for movement of a core element 21 with a strand layer 26 thereon in proximity to the chords 71L and 71R; as when the operating speed of the second machine 24 is becoming faster than desired. Switch 94 defines a lower limit for the moving core element 21 in proximity to the chords 72L and 72R; as when the operating speed of the second machine 24 is becoming slower than desired.
Referring to FIG. 11B, the opening of either limit switch, 93 or 94 (DSHLS or DSLLS), by contact with the shaft lug 92 of the speed controller unit 80 will de-energize relay DSR1. De-energization of relay DSR1 will open contacts DSR1B and DSR1C in a run hold circuit which will in turn open the relays R5-A and R5-C, stopping the drive motor 34 of each machine, 23 or 24. Opening of either limit switch, 93 or 94, will also energize relay DSR2 and close contacts DSR2A and DSR2B. Closing contact DSR2B will provide power to the "controller tripped" indicating light DL1 (110). After the operator has corrected whatever operating condition created the stoppage, the machines 23 and 24 are restored to operation by depressing the master run switch SW3 (112). The indicator light DL1 (110) can be turned off by depressing the "controller reset" button SW11 (111) to de-energize relay DSR2 and open contact DSR2B).
Second Tandem Mode of Operation When Machine 24 is "Master" and Machine 23 is "Slave"
This mode of operation is preferably used when the first machine 23 covers the moving core element 21 with a layer of strands 26 having a relatively steep braid angle and the second machine 24 covers the steep braid with a layer of strands 27 having a relatively flat braid angle.
In this mode, both machines, 23 and 24, are powered as described above for the first mode.
Referring to FIGS. 10, 11A, 11B and 11C, with switch 109 (SW1) in the right hand position for "second pass," contacts SW1A, SW1B and SW1D will be closed. The 110 V current from line 3-A provides power for relay R1-A through contact SW1A, and power for relays R3-A and R4-A through contact SW1B. The 110 V current from line 3-C provides power for relays R3-C and R4-C through contact SW1D. When relay R3-C is energized, contacts R3A-C, R3B-C and R3C-C are opened to isolate the potentiometer RC1-C, for the second machine 24, from the motor control circuit MC-24. Also, when relay R3-C is energized, contacts R3D-C, R3E-C and R3F-C are closed providing a circuit path through closed contacts R1D-C, R1E-C, and R1F-C for the potentiometer 105 (RC2C) to the motor control circuit. When relays R1-A and R3-A are energized, contacts R3A-A, R3B-A, R3C-A, R1D-A, R1E-A and R1F-A are opened to isolate both the potentiometer RC1-A, for the first machine 23, and the potentiometer 101 (RC2A) from the motor control circuit MC-23. Also, when relays R1-A and R3-A are energized, contacts R1A-A, R1B-A, R1C-A, R3D-A, R3E-A and R3F-A are closed providing a circuit path for the potentiometer 85 (DCR1) to the motor controller circuit MC-23. The contacts R1A-C, R1B-C and R1C-C remain open during operation of the machines, 23 and 24, in this mode. The system 20 will now be ready to enable the operator to select the base operating speed for the second machine 24.
FIG. 9 is intended to schematically show operating variables available to the operator in the second pass master-first pass slave mode. The input shaft 84 to the potentiometer 85 (DCR1) is intended to have a 90° total angular travel. At either side, an arc segment of 9° has been dedicated for use in stopping the operation of the drive motors 34 for each machine, 23 and 24. It has been found that an arc segment of 72° for movement of the wand 86 and roller 88 will enable the operator to effectively and accurately control the covering of a core element 21 at any operating speed chosen in the 10% to 90% range.
Referring again to FIGS. 10, 11B and 11C, the operator manually sets the potentiometer 105 (RC2C) to determine the base operating speed of the drive motor of the second machine 24. The roller 88 of the speed controller unit 80 is positioned so that the normally closed limit switches 93 and 94 (DSHLS and DSLLS, respectively) remain in a condition to energize the relay DSR1. The operator starts the machines 23 and 24 in tandem operation by momentarily depressing the "master run" button 112 (SW3).
The closing of contact SW3B provides 110 V current from line 3-C to relays R2-C and R5-C through contacts DSR1C, SW6B, SW7A, SW10B, SW3B, and R4D-C. Energizing relay R2-C opens contact R2A-C, which removes power from a suitably located safety or "motor off" indicator light L1-24. Energizing relay R5-C opens contact R5A-C and closes contacts R5B-C and R5C-C. The closing of contact R5B-C actuates the motor control circuit MC-24 to start operation of the second machine drive motor 34. Relay R5-C is held in an energized condition through contacts DSR1C, SW6B, SW7A, SW10B, SW2D, R6B-C and R5C-C.
Simultaneously, the closing of contact SW3A provides 110 V current from line 3-A to relays R2-A and R5-A through contacts DSR1B, SW7B, SW6A, SW10A, SW3A and R4D-A. Energizing relay R2-A opens contact R2A-A, which removes power from a suitably located safety or "motor off" indicator light L1-23. Energizing relay R5-A opens contact R5A-A and closes contacts R5B-A and R5C-A. The closing of contact R5B-A actuates the motor control circuit MC-23 to start operation of the first machine drive motor 34. Relay R5-A is held in an energized condition through contacts DSR1B, SW7B, SW6A, SW10A, SW2B, R6B-A and R5C-A.
In this mode, the operating speed and the power output of the drive motor for the second machine 24 is maintained constant, as determined by the operator setting of the potentiometer 105 (RC2C). The operating speed and the power output of the drive motor for the first machine 23 is automatically regulated by the potentiometer 85 of the speed controller unit 80.
Referring again to FIGS. 11A and 11C, the voltage output of the potentiometer 85 (DCR1) is transmitted to the motor control circuit MC-23. Any downward arcuate movement of the wand 86 and roller 88 will decrease the operating speed of the first machine drive motor. Any upward arcuate movement of the wand 86 and roller 88 will increase the operating speed of the firstmachine drive motor 34.
The safety or stop functions of the system 20, as described above with reference to the first mode of tandem operation, will also be operative in this mode.
Other Features
The operator may intentionally halt or stop both machines, 23 and 24, operating in either tandem mode, by depressing the "master emergency" stop button 114 (SW10) to de-energize the relays R5-A and R5-C.
The operator may simultaneously jog both machines, 23 or 24, operating in either tandem mode, by depressing the "master jog" button 113 (SW2). The closing of contact SW2A provides current for relay R5-A through contacts DSR1B, SW7B, SW6A, SW10A, SW2A and R4D-A, to operate the first machine 23. Simultaneously, the closing of contact SW2C provides current for relay R5-C through contacts DSR1C, SW6B, SW7A, SW10B, SW2C and R4D-C. When button 113 is continually depressed, contacts SW2B and SW2D are opened removing power from relays R6-A and R6-C which open contacts R6B-A and R6B-C in the run holding circuits. The machines, 23 and 24, will run only so long as button 113 (SW2) is depressed.
The connections between the operating buttons 116, 117 and 118 on the panel 115 of a control box 35 for each machine, 23 and 24, and electrical components depicted in FIGS. 11A and 11C have not been shown. It is considered that details of such connections could be supplied by a person of ordinary skill in the design and installation of electrical circuitry.
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A system and components thereof to control the covering of a flexible core with reinforcing strands by rotary braiding on tandem or adjacent machines. When used to control covering the core with multiple-braided strands formed in successive passes through tandem machines, the system has mechanical and electrical components which function to monitor and detect positions of the core, with a first covering of braided strands thereon, within and relative to the predetermined parameters of a chorded festoon and a zone of operational tolerance established between the machines, and to regulate the operating speed of both machines and of one machine relative to the other machine. In an alternative mode of control, the system has components permitting individual operation of each machine.
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