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FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not applicable. REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER LISTING APPENDIX Not applicable. COPYRIGHT NOTICE A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office, patent file or records, but otherwise reserves all copyright rights whatsoever. FIELD OF THE INVENTION The present invention relates generally to skin patches. More particularly, the invention relates to a skin patch that absorbs toxins from the body using infrared rays. BACKGROUND OF THE INVENTION Far infrared rays are thought to have the potential to be used to generate blood circulation in the body. In 1870, Dr. Pleasanton, a researcher in the United States, published research showing the relationship between light frequency and the rate of growth of cells and tissues, as well as their rate of cell division. Also, Dr. Neils Finsen, cured lesions and variola using red and infrared rays. More recent research performed by Tiina Karu, M.D., of the Laser Technology Center in Russia, holds that this spectrum of light speeds up cellular metabolic processes, such as, but not limited to, stimulating the activity of mitochondria, and triggering enzyme activity as well as the healing, regeneration, and normalization of damaged cell tissue. Sunshine is known to emit far infrared rays. Electricity can also generate far infrared rays. A method of far infrared generation with electricity is disclosed in U.S. Pat. No. 6,610,082. However, the conversion of sunshine or electricity to generate far infrared rays may not be an efficient method for promoting blood circulation and other cellular processes in the body. In view of the foregoing, there is a need for improved techniques for providing far infrared rays for use in promoting blood circulation and other cellular processes in the body that do not require sunshine or electricity. BRIEF DESCRIPTION OF THE DRAWINGS The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which: FIGS. 1A and 1B illustrate an exemplary toxin-absorbing patch, in accordance with an embodiment of the present invention. FIG. 1A shows the front of the patch, and FIG. 1B shows the back of the patch; and Table 1 lists an exemplary formula for the natural ingredients in a toxin-absorbing patch, according to an embodiment of the present invention. Unless otherwise indicated illustrations in the figures are not necessarily drawn to scale. SUMMARY OF THE INVENTION To achieve the forgoing and other objects and in accordance with the purpose of the invention, a skin patch for absorbing toxins from the body is presented. In one embodiment, a skin patch for absorbing toxins from a body is presented. The skin patch includes a first side having a heat reflective foil. A second side includes a non-woven rayon surface for absorbing the toxins. The rayon surface includes a plurality of openings for enhancing far infrared ray emission into a skin when the second side is placed in contact with the skin. A mixture of natural ingredients including vinegar, chitosan, loquat leaf, houttuynia cordata , vitamin C, tourmaline, vegetable fiber, and dextrin. The mixture is formulated to emit the far infrared emission, whereby blood circulation is promoted and perspiration and any toxins contained therein are absorbed by the rayon surface. In another embodiment a skin patch for absorbing toxins from a body is presented. The skin patch includes means for reflecting heat, means for absorbing the toxins, means for enhancing far infrared ray emissions into a skin and means for emitting the far infrared ray emissions, whereby blood circulation is promoted and perspiration and any toxins contained therein are absorbed by the absorbing means. Other features, advantages, and object of the present invention will become more apparent and be more readily understood from the following detailed description, which should be read in conjunction with the accompanying drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention is best understood by reference to the detailed figures and description set forth herein. Embodiments of the invention are discussed below with reference to the Figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. For example, it should be appreciated that those skilled in the art will, in light of the teachings of the present invention, recognize a multiplicity of alternate and suitable approaches, depending upon the needs of the particular application, to implement the functionality of any given detail described herein, beyond the particular implementation choices in the following embodiments described and shown. That is, there are numerous modifications and variations of the invention that are too numerous to be listed but that all fit within the scope of the invention. Also, singular words should be read as plural and vice versa and masculine as feminine and vice versa, where appropriate, and alternative embodiments do not necessarily imply that the two are mutually exclusive. The present invention will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings. Preferred embodiments of the present invention provide a toxin-absorbing patch that is used to generate far infrared rays from natural ingredients without the help of electricity and sunshine. Exemplary purposes of preferred embodiments of the present invention are to help improve blood circulation and to reduce waste and toxins in the body. In a preferred embodiment, a toxin-absorbing patch comprises powdered herbal ingredients. The patch is applied to the sole of a foot and emits far infrared rays onto the foot that causes the foot to perspire during application. The warmth from the far infrared rays helps improve blood circulation, and the perspiration absorbed into the patch may contain toxic waste such as, but not limited to, heavy metals. In preferred embodiments, the patch is easy to apply and works in six to eight hours of time. This allows for use during bedtime. In preferred embodiments, adhesive tape or a bandage is used to secure the toxin absorbing patch onto the skin. FIGS. 1A and 1B illustrate an exemplary toxin-absorbing patch 100 , in accordance with an embodiment of the present invention. FIG. 1A shows the front of patch 100 , and FIG. 1B shows the back of patch 100 . The front section of patch 100 is made from thin-layered titanium foil 103 , and the rear section of patch 100 is made from non-woven rayon 105 . Foil 103 provides a very smooth, shiny and reflective surface, which can reflect heat. Adhesive tape is applied to foil 103 on the front section of patch 100 for application. Rayon 105 on the rear section of patch 100 is applied directly onto the skin during use. Rayon 105 comprises openings 107 that offer enhanced far infrared ray emission into the skin. Patch 100 preferably has a width of 60 mm and a length of 80 to 90 mm; however, patches in alternate embodiments may be various shapes and sizes. Patch 100 has large surface area so that it can cover a large section of the body. The weight of patch 100 is preferably five grams with an error level of 0.2 grams; however, patches in alternate embodiments may weigh more or less. In the present embodiment, powdered natural ingredients are sealed inside patch 100 between foil 103 and rayon 105 . Patch 100 comprises a sachet between foil 103 and rayon 105 that has a bag opening into which the natural ingredients such as, but not limited to, vinegar, chitosan, loquat leaf, houttuynia cordata , vitamin C, tourmaline, vegetable fiber, and dextrin may be inserted. In the present embodiment, the bag section of the sachet is large and can be made to contain five to eight grams of ingredients. This mixture of natural ingredients is formulated to emit heat, or far infrared rays. Table 1 lists an exemplary formula for the natural ingredients in a toxin-absorbing patch, according to an embodiment of the present invention. Those skilled in the art, in light of the present teachings, will readily recognize that various other types of ingredients and amounts of ingredients may be used in alternate embodiments. In typical use of the present embodiment, patch 100 is applied externally on the surface of the skin. Patch 100 is attached to a bandage or adhesive tape before application to the skin. A user applies patch 100 to the skin by joining patch 100 to the bandage or adhesive tape with the edges of the bandage or adhesive tape extending beyond the edges of patch 100 and then attaching patch 100 with the adhesive tape or bandage to any location on the body that requires far infrared rays. Typically, the user applies patch 100 onto the bottom of a foot for six to eight hours. This allows for use during bedtime. During use, the foot produces sweat due to the heat coming from patch 100 , and the sweat may include toxins such as, but not limited to, heavy metals, which are absorbed into patch 100 . Therefore, a user that is suffering from heavy metal toxicity, for example, without limitation, a person with Autism, may benefit from the use of patch 100 because of the heavy metal reduction capability. The warmth from the far infrared rays also may help to improve blood circulation, and people suffering from blocked blood circulation may benefit from using patch 100 . In the present embodiment, patch 100 fits virtually any part of the body, is easy to use, and generally eliminates the need for electrical devices and interference. Patch 100 is made of non-allergic material, and may therefore be used by people who have allergies. Testing has shown that patches according to embodiments of the present invention may be used to emit heat when comprising a correct mixture of natural ingredients. Previously, only devices using electrical currents could be used to generate far infrared emission. Furthermore, an analysis of a new toxin-absorbing patch and a used toxin-absorbing patch was performed by Japan Food Research Laboratories on Dec. 2, 2005. The analysis tested for various heavy metals in the two patches including arsenic, lead, cadmium, mercury, tin, cobalt, and chromium. In the analysis only 0.01 parts per million (ppm) of cadmium was detected and none of the other metals were detected in the new patch while 0.55 ppm of lead, 0.03 ppm of cadmium, 0.09 ppm of cobalt, and 1.7 ppm of chromium were detected in the used patch. This analysis provides evidence that embodiments of the present invention may be used for the absorption of heavy metal from the body into the patch. Having fully described at least one embodiment of the present invention, other equivalent or alternative methods of providing toxin absorption and improving blood circulation using far infrared rays according to the present invention will be apparent to those skilled in the art. The invention has been described above by way of illustration, and the specific embodiments disclosed are not intended to limit the invention to the particular forms disclosed. For example, the particular implementation of the patch may vary depending upon the intended location of application. The patches described in the foregoing were directed to implementations typically applied to the bottom of the foot; however, similar techniques are to provide patches that are shaped to specifically fit on various parts of the body. For example, without limitation, large sheets may be used on the back or the back of the legs, curved patches may be used on the underarms, and small, round patches may be used on the hands. Implementations of the present invention that are applied to various areas of the body are contemplated as within the scope of the present invention. The invention is thus to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the following claims. TABLE 1 Ingredient Amount Wood Vinegar 0.60 grams Bamboo Vinegar 0.60 grams Chitosan 0.04 grams Loquat Leaf 0.04 grams Dokudami: Houttuynia Cordata 0.04 grams Vitamin C 0.04 grams Tourmaline 3.00 grams Vegetable fiber 0.20 grams Dextrin 0.44 grams Total: 5.00 grams
A skin patch for absorbing toxins from a body includes a first side having a heat reflective foil. A second side includes a non-woven rayon surface for absorbing the toxins. The rayon surface includes a plurality of openings for enhancing far infrared ray emission into a skin when the second side is placed in contact with the skin. A mixture of natural ingredients includes vinegar, chitosan, loquat leaf, houttuynia cordata , vitamin C, tourmaline, vegetable fiber, and dextrin. The mixture is formulated to emit the far infrared emission, whereby blood circulation is promoted and perspiration and any toxins contained therein are absorbed by the rayon surface.
0
BACKGROUND OF THE INVENTION [0001] This invention relates generally to washing machines, and more particularly, to methods and apparatus for controlling wash temperatures. [0002] Washing machines typically include a cabinet that houses an outer tub for containing wash and rinse water, a perforated clothes basket within the tub, and an agitator within the basket. A drive and motor assembly is mounted underneath the stationary outer tub to rotate the basket and the agitator relative to one another, and a pump assembly pumps water from the tub to a drain to execute a wash cycle. [0003] At least some known washing machines provide that an operator can select from three wash temperatures. Such machines have valve systems including hot and cold water valves. For a hot wash operation, for example, the hot water valve is turned on, i.e., opened, and for a cold wash operation, the cold valve is opened. For a warm wash, both the hot valve and cold valve are opened. The flow rates of water through the valves is selected so that the desired warm temperature is achieved using hot and cold water. [0004] The use of a pressure sensor to measure water level allows for more accurate control of multiple water levels compared to the use of a pressure switch. Unfortunately, this provides an opportunity for a single point error in the microprocessor hardware, or software to generate an over fill condition. At least one known system externally monitors the pressure sensor signal and generates a signal that opens a relay that breaks the line voltage to the water valve. The use of a relay adds a cost to the circuit. BRIEF DESCRIPTION OF THE INVENTION [0005] In one aspect, a circuit is provided. The circuit includes a processor programmed to prevent overfilling of a cabinet with a fluid, and a backup circuit having fixed logic. The backup circuit is electrically coupled to the processor to redundantly prevent overfilling the cabinet with the fluid. [0006] In another aspect, a washer overfill protection system is provided. The washer overfill protection system includes a pressure sensor configured to generate a variable frequency signal that is proportional to the fluid level of the washer, a converter electrically coupled to the pressure sensor, the converter is configured to generate an voltage that is proportional to the frequency of the output of the pressure sensor, and a microprocessor electrically coupled to the converter. The microprocessor is configured to calculate the fluid level from the voltage of the converter, and the microprocessor is electrically coupled to a fluid valve. The washer overfill protection system further includes a backup circuit having fixed logic. The backup circuit is electrically coupled to the converter and the fluid valve. The backup circuit is configured to at least one of turn on the fluid valve and turn off the fluid valve when the microprocessor fails. [0007] In a further aspect, a washing machine is provided. The washing machine includes a cabinet, a tub and basket mounted within the cabinet, a cold water valve for controlling flow of cold water to the tub, a hot water valve for controlling flow of hot water to the tub, and a circuit coupled to at least one of the hot water valve and the cold water valve to control opening and closing of the hot and cold water valves. The circuit includes a processor programmed to prevent overfilling of the cabinet and a backup circuit having fixed logic. The backup circuit is electrically coupled to the processor to redundantly prevent overfilling the cabinet. BRIEF DESCRIPTION OF THE DRAWINGS [0008] [0008]FIG. 1 is a perspective cutaway view of an exemplary washing machine. [0009] [0009]FIG. 2 is front elevational schematic view of the washing machine shown in FIG. 1. [0010] [0010]FIG. 3 is a schematic block diagram of a control system for the washing machine shown in FIGS. 1 and 2. [0011] [0011]FIG. 4 is a schematic diagram of a over fill protection circuit for the washing machine shown in FIGS. 1 and 2. DETAILED DESCRIPTION OF THE INVENTION [0012] [0012]FIG. 1 is a perspective view partially broken away of an exemplary washing machine 50 including a cabinet 52 and a cover 54 . A backsplash 56 extends from cover 54 , and a control panel 58 including a plurality of input selectors 60 is coupled to backsplash 56 . Control panel 58 and input selectors 60 collectively form a user interface input for operator selection of machine cycles and features, and in one embodiment a display 61 indicates selected features, a countdown timer, and other items of interest to machine users. A lid 62 is mounted to cover 54 and is rotatable about a hinge (not shown) between an open position (not shown) facilitating access to a wash tub 64 located within cabinet 52 , and a closed position (shown in FIG. 1) forming a substantially sealed enclosure over wash tub 64 . As illustrated in FIG. 1, machine 50 is a vertical axis washing machine. [0013] Tub 64 includes a bottom wall 66 and a sidewall 68 , and a basket 70 is rotatably mounted within wash tub 64 . A pump assembly 72 is located beneath tub 64 and basket 70 for gravity assisted flow when draining tub 64 . Pump assembly 72 includes a pump 74 and a motor 76 . A pump inlet hose 80 extends from a wash tub outlet 82 in tub bottom wall 66 to a pump inlet 84 , and a pump outlet hose 86 extends from a pump outlet 88 to an appliance washing machine water outlet 90 and ultimately to a building plumbing system discharge line (not shown) in flow communication with outlet 90 . [0014] [0014]FIG. 2 is a front elevational schematic view of washing machine 50 including wash basket 70 movably disposed and rotatably mounted in wash tub 64 in a spaced apart relationship from tub side wall 64 and tub bottom 66 . Basket 70 includes a plurality of perforations therein to facilitate fluid communication between an interior of basket 70 and wash tub 64 . [0015] A hot liquid valve 102 and a cold liquid valve 104 deliver fluid, such as water, to basket 70 and wash tub 64 through a respective hot liquid hose 106 and a cold liquid hose 108 . Liquid valves 102 , 104 and liquid hoses 106 , 108 together form a liquid supply connection for washing machine 50 and, when connected to a building plumbing system (not shown), provide a fresh water supply for use in washing machine 50 . Liquid valves 102 , 104 and liquid hoses 106 , 108 are connected to a basket inlet tube 110 , and fluid is dispersed from inlet tube 110 through a known nozzle assembly 112 having a number of openings therein to direct washing liquid into basket 70 at a given trajectory and velocity. A known dispenser (not shown in FIG. 2), may also be provided to produce a wash solution by mixing fresh water with a known detergent or other composition for cleansing of articles in basket 70 . [0016] In an alternative embodiment, a known spray fill conduit 114 (shown in phantom in FIG. 2) may be employed in lieu of nozzle assembly 112 . Along the length of the spray fill conduit 114 are a plurality of openings arranged in a predetermined pattern to direct incoming streams of water in a downward tangential manner towards articles in basket 70 . The openings in spray fill conduit 114 are located a predetermined distance apart from one another to produce an overlapping coverage of liquid streams into basket 70 . Articles in basket 70 may therefore be uniformly wetted even when basket 70 is maintained in a stationary position. [0017] A known agitation element 116 , such as a vane agitator, impeller, auger, or oscillatory basket mechanism, or some combination thereof is disposed in basket 70 to impart an oscillatory motion to articles and liquid in basket 70 . In different embodiments, agitation element 116 may be a single action element (i.e., oscillatory only), double action (oscillatory movement at one end, single direction rotation at the other end) or triple action (oscillatory movement plus single direction rotation at one end, singe direction rotation at the other end). As illustrated in FIG. 2, agitation element 116 is oriented to rotate about a vertical axis 118 . [0018] Basket 70 and agitator 116 are driven by motor 120 through a transmission and clutch system 122 . A transmission belt 124 is coupled to respective pulleys of a motor output shaft 126 and a transmission input shaft 128 . Thus, as motor output shaft 126 is rotated, transmission input shaft 128 is also rotated. Clutch system 122 facilitates driving engagement of basket 70 and agitation element 116 for rotatable movement within wash tub 64 , and clutch system 122 facilitates relative rotation of basket 70 and agitation element 116 for selected portions of wash cycles. Motor 120 , transmission and clutch system 122 and belt 124 collectively are referred herein as a machine drive system. [0019] Washing machine 50 also includes a brake assembly (not shown) selectively applied or released for respectively maintaining basket 70 in a stationary position within tub 64 or for allowing basket 70 to spin within tub 64 . Pump assembly 72 is selectively activated, in the example embodiment, to remove liquid from basket 70 and tub 64 through drain outlet 90 and a drain valve 130 during appropriate points in washing cycles as machine 50 is used. In an exemplary embodiment, machine 50 also includes a reservoir 132 , a tube 134 and a pressure sensor 136 . As fluid levels rise in wash tub 64 , air is trapped in reservoir 132 creating a pressure in tube 134 that pressure sensor 136 monitors. Liquid levels, and more specifically, changes in liquid levels in wash tub 64 may therefore be sensed, for example, to indicate laundry loads and to facilitate associated control decisions. In further and alternative embodiments, load size and cycle effectiveness may be determined or evaluated using other known indicia, such as motor spin, torque, load weight, motor current, and voltage or current phase shifts. [0020] Operation of machine 50 is controlled by a controller 138 which is operatively coupled to the user interface input located on washing machine backsplash 56 (shown in FIG. 1) for user manipulation to select washing machine cycles and features. In response to user manipulation of the user interface input, controller 138 operates the various components of machine 50 to execute selected machine cycles and features. [0021] In an illustrative embodiment, clothes are loaded into basket 70 , and washing operation is initiated through operator manipulation of control input selectors 60 (shown in FIG. 1). Tub 64 is filled with water and mixed with detergent to form a wash fluid, and basket 70 is agitated with agitation element 116 for cleansing of clothes in basket 70 . That is, agitation element is moved back and forth in an oscillatory back and forth motion. In the illustrated embodiment, agitation element 116 is rotated clockwise a specified amount about the vertical axis of the machine, and then rotated counterclockwise by a specified amount. The clockwise/counterclockwise reciprocating motion is sometimes referred to as a stroke, and the agitation phase of the wash cycle constitutes a number of strokes in sequence. Acceleration and deceleration of agitation element 116 during the strokes imparts mechanical energy to articles in basket 70 for cleansing action. The strokes may be obtained in different embodiments with a reversing motor, a reversible clutch, or other known reciprocating mechanism. [0022] After the agitation phase of the wash cycle is completed, tub 64 is drained with pump assembly 72 . Clothes are then rinsed and portions of the cycle repeated, including the agitation phase, depending on the particulars of the wash cycle selected by a user. [0023] [0023]FIG. 3 is a schematic block diagram of an exemplary washing machine control system 150 for use with washing machine 50 (shown in FIGS. 1 and 2). Control system 150 includes controller 138 which may, for example, be a microcomputer 140 coupled to a user interface input 141 . An operator may enter instructions or select desired washing machine cycles and features via user interface input 141 , such as through input selectors 60 (shown in FIG. 1) and a display or indicator 61 coupled to microcomputer 140 displays appropriate messages and/or indicators, such as a timer, and other known items of interest to washing machine users. A memory 142 is also coupled to microcomputer 140 and stores instructions, calibration constants, and other information as required to satisfactorily complete a selected wash cycle. Memory 142 may, for example, be a random access memory (RAM). In alternative embodiments, other forms of memory could be used in conjunction with RAM memory, including but not limited to flash memory (FLASH), programmable read only memory (PROM), and electronically erasable programmable read only memory (EEPROM). [0024] Power to control system 150 is supplied to controller 138 by a power supply 146 configured to be coupled to a power line L. Analog to digital and digital to analog converters (not shown) are coupled to controller 138 to implement controller inputs and executable instructions to generate controller output to washing machine components such as those described above in relation to FIGS. 1 and 2. More specifically, controller 138 is operatively coupled to machine drive system 148 (e.g., motor 120 , clutch system 122 , and agitation element 116 shown in FIG. 2), a brake assembly 151 associated with basket 70 (shown in FIG. 2), machine water valves 152 (e.g., valves 102 , 104 shown in FIG. 2) and machine drain system 154 (e.g., drain pump assembly 72 and/or drain valve 130 shown in FIG. 2). In a further embodiment, water valves 152 are in flow communication with a dispenser 153 (shown in phantom in FIG. 3) so that water may be mixed with detergent or other composition of benefit to washing of garments in wash basket 70 . [0025] In response to manipulation of user interface input 141 controller 138 monitors various operational factors of washing machine 50 with one or more sensors or transducers 156 , and controller 138 executes operator selected functions and features according to known methods. Of course, controller 138 may be used to control washing machine system elements and to execute functions beyond those specifically described herein. Controller 138 operates the various components of washing machine 50 in a designated wash cycle familiar to those in the art of washing machines. [0026] [0026]FIG. 4 is a schematic of a washer overfill protection circuit 200 . Washer overfill protection circuit 200 includes a pressure sensor 210 electrically coupled to a frequency to voltage converter 215 . The output of frequency to voltage converter 215 is electrically coupled to at least a first circuit 220 and a second circuit 225 . In the exemplary embodiment, first circuit 220 is a back up circuit 220 and includes a first operational amplifier (op amp) 230 and a second op amp 235 . In one embodiment, first op amp 230 is a overfill comparator 230 and second op amp 235 is a sensor error comparator 235 . Overfill comparator 230 and sensor error comparator 235 are electrically coupled to a first gate 240 . First gate 240 is electrically coupled to a second gate 245 and a third gate 248 . Second gate 245 is electrically coupled to a first transistor 250 , such as a bipolar junction transistor. First transistor 250 is electrically coupled to a first relay driver 255 . First relay driver 255 is electrically coupled to a fluid valve coil 260 , such as a hot water valve coil 260 . [0027] Second circuit 225 includes a microprocessor 270 . Microprocessor 270 is electrically coupled to second gate 245 of back up circuit 220 and a third gate 248 . Third gate 248 is electrically coupled to a second transistor 285 , such as a bipolar junction transistor. Second transistor 285 is electrically coupled to a second relay driver 290 . Second relay driver 290 is electrically coupled to a fluid valve coil 300 , such as a cold water valve coil 300 . [0028] Microprocessor 270 is programmed to perform functions described herein, and as used herein, the term microprocessor is not limited to just those integrated circuits referred to in the art as microprocessor, but broadly refers to computers, processors, microcontrollers, microcomputers, programmable logic controllers, application specific integrated circuits, and other programmable circuits, and these terms are used interchangeably herein. [0029] Pressure sensor 210 generates a variable frequency signal that is proportional to the water level in washer tub 64 . Frequency to voltage converter 215 generates an analog voltage that is proportional to the frequency from the output of pressure sensor 210 . The analog voltage is then input to microprocessor 270 . Microprocessor 270 uses the analog voltage to calculate the water level and sends, for example, a hot water valve command signal to turn on and off hot water valve coil 260 . The hot water valve command and pressure sensor check signal are sent to the input of second gate 245 . If hot water command is high and the pressure sensor check signal is high, the output of second gate 245 is high, turning on first transistor 250 . If first transistor 250 is on, first relay driver 255 is energized, closing the normally closed contact for first relay driver 255 energizing hot water valve coil 260 . Energizing hot water valve coil 260 opens the hot water valve (not shown), allowing hot water to flow into washer tub 64 . If the hot water valve command and/or the pressure sensor check signal is low, the output of second gate 245 is low, turning off first transistor 250 . If first transistor 250 is off, first relay driver 255 is de-energized, opening the normally open contacts of first relay driver 255 , de-energizing hot water valve coil 260 . De-energizing hot water valve coil 260 shuts off the hot water valve, blocking hot water from entering the washer tub 64 . [0030] The output of the frequency to voltage converter 215 is input into overfill comparator 230 and compared with an over fill reference voltage. If the frequency to voltage converter 215 output is less than the over fill reference voltage, the overfill comparator 230 output is high, indicating a normal tub water level. If the frequency to voltage converter 215 output is greater than the over fill reference voltage, the overfill comparator 230 output is low, indicating an over fill condition. [0031] The output of the frequency to voltage converter 215 is also an input into sensor error comparator 235 and compared with a sensor error voltage. If the frequency to voltage converter 215 output is greater than the sensor error voltage, the sensor error comparator 235 output is high indicating a valid pressure sensor signal. If the frequency to voltage converter 215 output is less than the sensor error voltage, the sensor error comparator 235 output is low indicating an invalid pressure sensor signal. [0032] Overfill comparator 230 output and sensor error comparator 235 output are connected to the input of first gate 240 . If overfill comparator 230 output and/or sensor error comparator 235 output is low, first gate 240 output is low. If the output of first gate 240 is low, second gate 245 and third gate 248 outputs are low, de-energizing first transistor 250 and second transistor 285 . De-energizing first transistor 250 and second transistor 285 de-energizes first relay driver 255 and second relay driver 290 , respectfully, de-energizing hot and cold water valve coils 260 and 300 , respectfully. De-energizing hot and cold water valve coils 260 and 300 , blocks the hot and cold water from entering washer tub 64 . [0033] In one embodiment, pressure sensor 210 may output an analog voltage instead of a frequency signal, thereby removing frequency to voltage converter 215 from circuit 200 . In another embodiment, the logic performed by first, second, and third gates 240 , 245 , and 248 may be performed by other logic that generates the same operation. In addition, the water valve driver circuits may be generated by any other switching device. In a further embodiment, hot and cold water valve coils 260 and 300 may be replaced by dc water valves, using a dc drive circuit instead of first and second relay drivers 255 and 290 . [0034] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
A circuit is provided. The circuit includes a processor programmed to prevent overfilling of a cabinet with a fluid and a backup circuit having fixed logic. The backup circuit is electrically coupled to the processor to redundantly prevent overfilling the cabinet with the fluid.
3
CROSS REFERENCE TO RELATED APPLICATIONS [0001] The present application is a divisional of U.S. patent application Ser. No. 12/306,706, filed Jul. 20, 2009, which is a U.S.C. §371 National Phase conversion of PCT/JP2007/063011, filed Jun. 28, 2007, which claims benefit of Japanese Application No. 2006-177971, filed Jun. 28, 2006 and Japanese Application No. 2007-056624, filed Mar. 7, 2007, the contents of which are incorporated in full herein by reference. The PCT International Application was published in the Japanese language. FIELD OF THE INVENTION [0002] The present invention relates to a drug, a drug guidance system, a magnetic detection system, and a drug design method. BACKGROUND [0003] Generally, drugs administered to the living body reach target sites and cause therapeutic effects by exerting pharmacological effects at the localized target sites. However, there will not be a cure if drugs reach tissues other than the target sites (that is, normal tissues). Consequently, how to guide drugs to the target sites efficiently is important in terms of therapeutic strategy. Such a technology for guiding drugs to the target sites is called drug delivery and research and development thereof have been actively carried out in recent years. These drug delivery methods have at least two merits. One is that a sufficiently high drug concentration is obtained in affected tissues. This is advantageous because pharmacological effects are achieved only when the drug concentration in the target site is higher than a certain value, and therapeutic effects can not be expected when the concentration is low. Second is that the drug delivery methods guide drugs to affected tissues only and do not guide drugs to normal tissues unnecessarily. Side effects can thereby be suppressed. [0004] Such drug delivery methods exert their effects most in cancer treatments using anticancer agents. Since most anticancer agents suppress cell growth of cancer cells which are actively dividing, they also suppress cell growth in normal tissues where cells are actively dividing such as, for example, bone marrow, hair-roots, or gastrointestinal mucosa. On this account, side effects such as anemia, hair loss, and vomiting appear in cancer patients who have received administration of anticancer agents. Dosage has to be restricted since these side effects would be heavy burdens on patients and thus, there is a problem in that pharmacological effects of anticancer agents cannot be obtained sufficiently. Furthermore, there is a concern of patients dying due to the side effects in worst cases. Accordingly, it is hoped that cancer treatments can be carried out efficiently while suppressing the side effects by guiding the anticancer agents until they reach cancer cells with drug delivery methods and allowing the agents to exert their pharmacological effects on cancer cells, specifically. [0005] Apart from anticancer agents, for example, application of the drug delivery methods to agents for treating male erectile dysfunction is considered. There are examples of significant systemic hypotension resulting in deaths caused by the use of agents for treating male erectile dysfunction when combined with nitro preparations and thus, it is a problem particularly for males of middle and old age with heart disease. This is because the agents for treating erectile dysfunction do not necessarily concentrate at the target site, act on systemic blood vessels, and thereby increase vasodilation effects of nitro preparations. Accordingly, it is considered that the side effects resulting from the combined use with nitro preparations can be suppressed by guiding the agents for treating male erectile dysfunction until they reach the target site with drug delivery methods and allowing the agents to exert their pharmacological effects on the target site specifically. [0006] As a specific method of drug delivery methods, for example, guidance to the target site using supports (carriers) is being studied and this method is to load drugs onto supports that tend to concentrate in the target site and thereby make the supports transport the drugs to the target site. As supports, use of various types of antibodies, microspheres, or magnetic bodies has been discussed. Among them, magnetic bodies are those that are regarded as particularly hopeful and a method to attach the supports, which are magnetic bodies, to the drugs and make them accumulate in the target site by means of a magnetic field has been examined (for example, refer to the following Patent Document 1). Since this guiding method is easy and simple and makes treatment which targets the target site possible, it is considered to be an effective method especially for anticancer agents with high cytotoxicity. Patent Document 1: Japanese Laid-Open Patent Application No. 2001-10978 BRIEF SUMMARY OF THE INVENTION [0008] However, when the supports, which are magnetic bodies, are used as carriers as described above, difficulties in oral administration, the large size of carrier molecules in general, or technical problems in bond strength and affinity with the drug molecules have been pointed out and thus, practical application has been difficult. [0009] The present invention addresses the abovementioned problems, with an object of realizing a drug delivery system which is capable of solving conventional technical problems and which is easy to put into practical application. [0010] In order to achieve the above object according to a first aspect of the present invention relating to a drug, the drug is composed of an organic or inorganic compound, and is made magnetic by modification of side chains and/or crosslinking between side chains. [0011] According to a second aspect of the present invention relating to a drug, the organic compound in the first aspect is forskolin. [0012] Moreover, as a third aspect of the present invention relating to a drug according to the first aspect, the organic compound is a composition effective in the treatment of male erectile dysfunction. [0013] Moreover, as a fourth aspect of the present invention relating to a drug according to the first aspect, the inorganic compound is a metal complex. [0014] Moreover, as a fifth aspect of the present invention relating to a drug according to the fourth aspect, the metal complex is a cis geometric isomer with anticancer properties. [0015] Moreover, as a sixth aspect of the present invention relating to a drug according to the fifth aspect, the cis geometric isomer is cisplatin. [0016] Moreover, as a first aspect of the present invention relating to a drug guidance system, a drug of any one of the above first to sixth aspects administered to a body is guided to a predetermined target site using the magnetism of the drug. [0017] Moreover, as a first aspect of the present invention relating to a magnetic detection system, by detecting magnetism of a drug of any one of the above first to sixth aspects administered in a body, the dynamics of the drug are detected. [0018] Moreover, as a first aspect of the present invention relating to a drug design method, a molecular model having modified side chains and/or crosslinked side chains is set with respect to an organic or inorganic compound used as a drug; whether or not the molecular model is magnetic is determined from a spin-charge density distribution obtained by a numerical calculation for the molecular model; and then the drug is designed based on the molecular model that has been determined to be magnetic. [0019] Moreover, as a second aspect of the present invention relating to a drug design method according to the first aspect, whether the molecular model is ferromagnetic or ferrimagnetic is determined based on the spin-charge density distribution. [0020] Moreover, as a third aspect of the present invention relating to a drug design method according to in the first aspect, the magnetic strength of the molecular model is determined based on the spin-charge density distribution. [0021] According to the present invention, since drugs themselves will be magnetic, it is possible to guide the drugs to the target sites in the body by use of magnetism of the drugs themselves without using supports made from magnetic bodies as in the conventional cases. As a result, conventional problems such as difficulties in oral administration, the large size of carrier molecules in general, or technical problems in bond strength and affinity with the drug molecules can be resolved. Furthermore, it is possible to realize a drug delivery system which is easy to put into practical application. BRIEF DESCRIPTION OF THE DRAWINGS [0022] FIG. 1 is a diagram of a basic molecular structural model of forskolin in one embodiment of the present invention. [0023] FIG. 2 is a diagram of a molecular structural model of a ferrimagnetic forskolin derivative A in one embodiment of the present invention. [0024] FIG. 3 is a diagram showing a three-dimensional molecular structural model of the forskolin derivative A and its spin-charge density distribution, in one embodiment of the present invention. [0025] FIG. 4 is a diagram of a molecular structural model of a ferromagnetic forskolin derivative B in one embodiment of the present invention. [0026] FIG. 5 is a diagram showing a three-dimensional molecular structural model of the forskolin derivative B and its spin-charge density distribution, in one embodiment of the present invention. [0027] FIG. 6 is a flow chart of a drug design method in one embodiment of the present invention. [0028] FIG. 7 shows a diagram of a basic molecular structural model of PDE 5 inhibitor with a standard composition and a three-dimensional molecular structure and spin-charge density distribution of the PDE 5 inhibitor with a standard composition in one embodiment of the present invention. [0029] FIG. 8 shows a diagram of a basic molecular structural model of a derivative of PDE 5 inhibitor and a three-dimensional molecular structural model and spin-charge density distribution of the derivative of PDE 5 inhibitor in one embodiment of the present invention. [0030] FIG. 9 is a diagram of a basic molecular structural model of cisplatin in one embodiment of the present invention. [0031] FIG. 10 shows a diagram of a basic molecular structural model of a cisplatin derivative (Cis-Pt-a3) and a three-dimensional molecular structural model and spin-charge density distribution of the cisplatin derivative (Cis-Pt-a3) in one embodiment of the present invention. [0032] FIG. 11 is an analytical result of spin-charge densities of a cisplatin derivative and a derivative derived by the substitution of platinum of the cisplatin derivative into another metal element in one embodiment of the present invention. [0033] FIG. 12 is a diagram of a basic molecular structural model of the cisplatin derivative NK121, and its three-dimensional molecular structural model and spin-charge density distribution in one embodiment of the present invention. [0034] FIG. 13 is a diagram showing a hydrolysis process of cisplatin in a living body in one embodiment of the present invention. [0035] FIG. 14 is a diagram of a three-dimensional molecular structural model and spin-charge density distribution of the cisplatin hydrolysate [Pt(OH 2 ) 2 (dien)] 2+ in one embodiment of the present invention. [0036] FIG. 15 is a first example of a computer output screen indicated by the computer simulation program during the process of calculating the spin-charge density of the target compound. [0037] FIG. 16 is a second example of a computer output screen indicated by the computer simulation program during the process of calculating the spin-charge density of the target compound. [0038] FIG. 17 is a diagram illustrating the principle of MRI. [0039] FIG. 18 is a perspective view of the entire MRI system. [0040] FIG. 19 shows MRI output images of an example in which a magnetic drug is administered to a rat. [0041] FIG. 20 is an MRI output image showing that MRI images are dependent on the concentration of a target drug. [0042] FIG. 21 is a block diagram illustrating the outline of an experiment system for verifying the location of a drug in a magnetic field. [0043] FIG. 22 is a chart showing characteristics of the measurement results of the number of cells in accordance with fluctuations in the drug concentration in a magnetic field. [0044] FIG. 23 is a perspective view illustrating another embodiment of a guidance system according to the present invention. [0045] FIG. 24 is a graph showing the MRI measurement results on mouse kidneys. DESCRIPTION OF REFERENCE SYMBOLS [0000] A, B: forskolin derivatives DETAILED DESCRIPTION OF THE INVENTION [0047] Hereunder is a description of one embodiment of the present invention, with reference to the drawings. First Embodiment [0048] Firstly, the first embodiment is described using an organic compound, more specifically, forskolin, as a drug candidate agent. [0049] FIG. 1 is a diagram showing a basic molecular structural model of forskolin. In this drawing, R 6 , R 7 , and R 13 show positions bonded with an atom or a molecule for modifying a side chain of forskolin. Depending on the type of atom or molecule bonded to these positions, the physical property of forskolin varies. In this drawing, one having H bonded to R 6 , CH 3 bonded to R 7 , and CH═CH 2 bonded to R 13 is naturally occurring forskolin, and one having the side chain structure changed artificially, that is, forskolin produced by changing the atom or molecule for modifying R 6 , R 7 , and R 13 , is called a forskolin derivative. In FIG. 1 , C 1 to C 13 represent a carbon atom (C). [0050] FIG. 2 is a diagram showing a basic molecular structural model of a magnetic (ferrimagnetic) forskolin derivative A. As shown in this drawing, the forskolin derivative A is one where R 6 of the abovementioned naturally occurring forskolin is changed into COCH 2 CH 2 NCH 3 , R 7 is changed to CH 3 , and the oxygen atom (O) bonded to C 9 and the carbon atom bonded to C 13 are crosslinked. [0051] FIG. 3 shows a three-dimensional molecular structure of the forskolin derivative A ad its spin-charge density distribution obtained by a computer simulation based on a well-known first principle molecular dynamics method. The first principle molecular dynamics method is disclosed in Delley, B. J. Chem. Phys., 1990, 92, 508-517, Delley, B. J. Chem. Phys., 2000, 113, 7756-7764, Haselgrove, C. B. Math Comp., 1961, 15, 323-337, Ellis, D. E. Int. J. Quantum Chem., 1968, 2S, 35-42, Ellis, D. E.; Painter, G. S. Phys. Rev. B, 1970, 2, 2887-2898. [0052] In FIG. 3 , region 1 shows a downward spin-charge density, and regions 2 to 5 show upward spin-charge densities. These regions are selected because, as a result of calculation of a contour line of the spin-charge densities, these region show high spin-charge densities. The property of magnetism of a compound is decided by balance between upward spin and downward spin. Therefore, as shown in FIG. 2 , since a downward spin state 1 ′ and upward spin states 2 ′ to 5 ′ are mixed in the forskolin derivative A, it is found to be a ferrimagnetic body. [0053] On the other hand, FIG. 4 is a diagram showing a basic molecular structural model of a magnetic (ferromagnetic) forskolin derivative B. As shown in this drawing, the forskolin derivative B is one where R 6 of the abovementioned naturally occurring forskolin is changed into COCH 2 CH 2 NCH 3 , R 7 is CH 3 , R 13 is changed into CH—CH 2 —CH 3 , and the oxygen atom bonded to C 9 and the carbon atom bonded to C 13 are crosslinked. [0054] Similarly to the above, FIG. 5 shows a three-dimensional molecular structure of the forskolin derivative B and its spin-charge density distribution obtained by a computer simulation based on the first principle molecular dynamics method. In FIG. 5 , regions 10 to 12 show upward spin-charge densities. Therefore, as shown in FIG. 4 , since only upward spin states 10 ′ to 12 ′ are present in the forskolin derivative B, it is found to be a ferromagnetic body. [0055] In this manner, by modifying the side chains of forskolin with specified atoms or molecules, and crosslinking between side chains present in predetermined positions, a magnetic forskolin derivative, that is, a drug, can be produced. The portion indicated with a dashed line in FIG. 2 is crosslinked. In this way, the magnitude of the magnetism of the drug can be controlled by modifying the side chains of the drug with specified atoms or molecules and/or crosslinking the side chains existing at specified positions. A user can decide as appropriate, by means of computer simulation, which functional group to insert or what form of crosslinking should be applied. [0056] A system for realizing this computer simulation is equipped with known hardware resources for a computer: in other words, the system includes memory, an arithmetic unit with arithmetic circuits such as CPU, and display means for outputting arithmetic results. The memory stores data for specifying the three-dimensional structure of existing organic compounds and inorganic compounds and software programs for realizing the computer simulation. The software can add, change, or delete the side chains of each compound, crosslink specified side chains, calculate regions with high spin-charge densities as described above, and determine the spin-charge density of the entire structure. As such a program, for example, a commercially available product (Dmol3 made by Accelrys K.K.) can be used. [0057] The user inputs the position(s) to add side chains, changes the side chains, or selects the side chains to be deleted; and the user further designates the position(s) to form crosslinks to the arithmetic unit using a support program for the memory. Receiving such input values, the arithmetic unit calculates the spin-charge density and outputs the results to a display screen. Moreover, the user can find the spin-charge density of an existing compound by adding structural data of the existing compound to the computer system. [0058] Next, a method for designing such a magnetic drug will be explained below. FIG. 6 is a flow chart showing a processing procedure of the present drug design method. The processing described hereunder is performed in a computer simulation program based on the first principle molecular dynamics method. [0059] Firstly, since there are more than 200 types of forskolin derivatives used as drugs, a forskolin derivative serving as an evaluation target is selected from among them, and its chemical formula is input into the computer simulation program (step S 1 ). Here, a case where the abovementioned forskolin derivative A is selected as the forskolin derivative is assumed and described hereunder. A derivative of each type of these compounds is identified by a compound library created in advance. The user inputs' the atomic number and position of each atom of each compound to the arithmetic unit. [0060] FIG. 15 shows screens displayed on the output device during operation in step 1 . As shown in FIG. 15 ( 1 ), the atomic number and atomic coordinates of one atom are input. As shown in FIG. 15 ( 2 ), the bonded state of atoms such as a single bond, a double bond, or a triple bond is specified by placing a cursor at the relevant position and clicking the cursor. [0061] The arithmetic unit receiving the above input sets, based on the above-mentioned program, initial values of upward spin (spin up) wave function φ↑(r), downward spin (spin down) wave function φ↓(r), spin-up effective potential v↑(r), spin-down effective potential v↓(r), spin-up charge density ρ↑(r), and spin-down charge density ρ↓(r) (step S 2 ). Here, r is a variable showing the coordinates in the three-dimensional space. [0062] In a case where the respective atoms constituting the forskolin derivative A are present as an isolated atom in the three-dimensional space, the spin-up wave functions φ↑(r) are obtained for each of the respective atoms. The initial value of the spin-up wave function φ↑(r) is the sum of all the spin-up wave functions φ↑(r) that have been obtained in such a manner. [0063] Similarly, the initial value of the spin-down wave function φ↓(r) is the sum of all the spin-down wave functions φ↓(r) obtained for each of the respective atoms, in a case where the respective atoms are present as an isolated atom in the three-dimensional space. Moreover, based on the spin-up wave functions φ↑(r) in a case where the respective atoms constituting the forskolin derivative A are present as an isolated atom in the three-dimensional space, the spin-up effective potentials v↑(r) are obtained for each of the respective atoms. The initial value of the spin-up effective potential v↑(r) is the sum of all the spin-up effective potentials v↑(r) that have been obtained for each of the respective atoms. Similarly, the initial value of the effective potential v↓(r) is the sum of all the spin-down effective potentials v↓(r) obtained for each of the respective atoms based on the spin-down wave functions φ↓(r) in a case where the respective atoms are present as an isolated atom in the three-dimensional space. [0064] Moreover, the initial value of the spin-up charge density ρ↑(R) is obtained by substituting the spin-up wave functions φ↑(r) that have been obtained for each of the respective atoms as mentioned above, into the following operational expression (1). Moreover, the initial value of the spin-down charge density ρ↓(r) is obtained by substituting the spin-down wave functions φ↓(r) that have been obtained for each of the respective atoms, into the following operational expression (2). In the following operational expression (1), φ↑(r) is a conjugate complex number of the spin-up wave function φ↑(r). In the following operational expression (2), φ↓*(r) is a conjugate complex number of the spin-down wave function φ↓(r). [0000] [Equation 1] [0000] ρ ↑ ( r )=ΣΦ ↑ *( r )Φ ↑ ( r )  (1) [0000] ρ ↓ ( r )=ΣΦ ↓ *( r )Φ η ( r )  (1) [0065] Next, based on the initial values of the spin-up effective potential v↑(r) and the spin-down effective potential v↓(r), and the initial values of the spin-up charge density ρ↑(r) and the spin-down charge density ρ↓(r), the following Kohn-Sham equations (3) and (4) are solved, so as to calculate the spin-up wave function φ↓(r), the spin-down wave function φ↓(r), the spin-up energy eigenvalue ε↑, and the spin-down energy eigenvalue ε↓, of the forskolin derivative A (step S 3 ). [0000] [Equation 2] [0000] [−½∇ 2 +V ↑ {r ,ρ ↑ ( r )}]Φ ↑ ( r )=ε ↑ Φ ↑ ( r )  (3) [0000] [−½∇ 2 +V ↓ {r ,ρ ↓ ( r )}]Φ ↓ ( r )=ε ↓ Φ ↓ ( r )  (3) [0066] Then, based on the spin-up wave function φ↑(r) and the spin-down wave function φ↓(r) of the forskolin derivative A obtained in step S 3 , the spin-up charge density ρ↑(r), the spin-down charge density ρ↓(r), the spin-up effective potential v↑(r), and the spin-down effective potential v↓(r) of the forskolin derivative A are calculated (step S 4 ). It is then determined whether or not these spin-up charge density ρ↑(r) and spin-down charge density ρ↓(r) are the same as the previous values of the spin-up charge density ρ↑(r) and the spin-down charge density ρ↓(r), which are the initial values in this case (step S 5 ). In this step S 5 , if it is determined “NO”, that is, the previous values (initial values) of the spin-up charge density ρ↑(r) and the spin-down charge density p↓(r) are not the same as the present values obtained in step S 4 , then the spin-up effective potential v↑(r), the spin-down effective potential v↓(r), the spin-up charge density ρ↑(r), and the spin-down charge density ρ↓(r) obtained in step S 4 are set as new initial values (step S 6 ). Then the flow proceeds to step S 3 , and the Kohn-Sham equations (3) and (4) are solved again, so as to calculate a new spin-up wave function φ↑(r), spin-down wave function φ↓(r), spin-up energy eigenvalue ε↑, and spin-down energy eigenvalue ε↓. That is, in step S 5 , the processing from steps S 3 to S 6 is repeated until the previous values of the spin-up charge density ρ↑(r) and the spin-down charge density ρ↓(r) become equal to the present values, to thereby obtain the spin-up wave function φ↑(r), the spin-down wave function φ↓(r), the spin-up energy eigenvalue ε↑, and the spin-down energy eigenvalue ε↓(r) which satisfy the Kohn-Sham equations (3) and (4). [0067] On the other hand, in step S 5 , if it is determined “YES”, that is, the previous values of the spin-up charge density ρ↑(r) and the spin-down charge density ρ↓(r) are the same as the present values, then as described above, an interatomic force acting between respective atoms is calculated, based on the spin-up wave function φ↑(r), the spin-down wave function φ↓(r), the spin-up energy eigenvalue ε↑, and the spin-down energy eigenvalue ε↓(r) which satisfy the Kohn-Sham equations (3) and (4), and the structure of the forskolin derivative A is optimized (step S 7 ). That is, the spin-up wave function φ↑(r), the spin-down wave function φ↓(r), and so forth that have been obtained by repeating steps S 3 to S 6 , are merely the optimum values in a model on a two-dimensional plane as shown in FIG. 2 , and in practice it is necessary to consider the structure of the forskolin derivative A in the three-dimensional space. [0068] Specifically, in step S 7 , the respective atoms constituting the forskolin derivative A are moved for a predetermined distance in an optimum direction assumed from the spin-up wave function φ↑(r), and the spin-down wave function φ↓(r), in the three-dimensional space, and an interatomic force acting between the respective atoms at this time is calculated. If the interatomic force at this time becomes 0 and the respective atoms no longer move, it can be determined that the structure of the forskolin derivative A is optimized. Therefore, the interatomic force acting between the respective atoms after the movement is calculated, and it is, determined whether or not the interatomic force becomes 0 (step S 8 ). [0069] In this step S 8 , if it is determined “NO”, that is, the interatomic force is not 0 and the structure is not optimized, then the spin-up wave functions φ↑(r) and the spin-down wave functions φ↓(r) in the structures of the respective atoms after the movement are obtained. Then, the spin-up effective potential v↑(r), the spin-down effective potential v↓(r), the spin-up charge density ρ↑(r), and the spin-down charge density ρ↑(r) obtained from the spin-up wave function φ↑(r) and the spin-down wave function φ↓(r) are set as new initial values (step S 9 ), and the processing from steps S 3 to S 8 is repeated. Here, the reason the flow returns to step S 3 is that the spin-up wave function φ↑(r) and the spin-down wave function φ↓(r) are changed according to the structural change of the respective atoms after the movement. Moreover, the structures of the respective atoms after the movement are memorized, and when step S 7 is performed again, the respective atoms are moved again for a predetermined distance from the previous structure. [0070] When the structure of such a forskolin derivative A is optimized, then as shown in FIG. 2 , the three-dimensional structure is forcibly altered so as to crosslink the oxygen atom bonded to C 9 and the carbon atom bonded to C 13 . The atoms selected for such a crosslinking can be optionally changed. [0071] On the other hand, in this step S 8 , if it is determined “YES”, that is, the interatomic force acting between the respective atoms becomes 0 and the structure of the forskolin derivative A is optimized by, for example, Jahn-Teller effect, then the spin-charge density distribution as shown in FIG. 3 is obtained, based on the spin-up wave function φ↑(r) and the spin-down wave function φ↓(r) in the optimized structure (step S 10 ). [0072] Here, depending on the forskolin derivative selected as the evaluation target, the spin-charge density distribution such as regions 1 to 5 shown in FIG. 3 is not generated, or if the spin-charge density distribution is generated, regions having only a very small amount of spin-charge density (that is magnetic strength) are present. Such a forskolin derivative can not be determined to be magnetic. Consequently, based on the spin-charge density distribution, firstly it is determined whether or not the forskolin derivative selected as the evaluation target is magnetic (step S 11 ). [0073] In step S 11 , if it is determined “NO”, that is, the forskolin derivative selected as the evaluation target is not magnetic, the flow proceeds to step S 1 , and another forskolin derivative is newly selected and the magnetism is evaluated again. On the other hand, in step S 11 , if it is determined “YES”, that is, the forskolin derivative selected as the evaluation target is magnetic, then it is determined whether it is ferromagnetic or ferrimagnetic, based on the spin-charge density distribution (step S 12 ). [0074] As described above, since the spin-charge density distribution shows the distribution of the spin-up charge density and the spin-down charge density; if these spin-up charge density and spin-down charge density are mixed, it can be determined to be ferrimagnetic. If only one of the spin-up charge density and the spin-down charge density is present, it can be determined to be ferromagnetic. [0075] As shown in FIG. 3 , since the spin-up charge densities (regions 2 to 5 ) and the spin-down charge density (region 1 ) are mixed in the forskolin derivative A, it is determined to be a ferrimagnetic forskolin derivative (step S 13 ). On the other hand, for example, if the selected forskolin derivative is the forskolin derivative B, as shown in FIG. 5 , only the spin-up charge densities (regions 10 to 12 ) are present. Therefore, it is determined to be a ferromagnetic forskolin derivative (step S 14 ). It is also possible to obtain the magnetic strength based on the spin-charge density distribution. Incidentally, in the above-mentioned examples, side chains of a compound are portions indicated with R 6 , R 7 , R 13 in FIG. 1 and main chains are portions excluding the above-mentioned side chain portions from the structural formula in FIG. 1 . [0076] As described above, according to the present drug design method and design system, the magnetism of a forskolin derivative having side chains modified with various atoms or molecules, and side chains optionally crosslinked can be determined. Moreover, by producing a forskolin derivative based on a molecular model determined to be magnetic, a magnetic drug can be manufactured. Therefore, it is possible to guide the drugs to the target sites in the body by use of magnetism of the drugs themselves without using supports (carriers) made from magnetic bodies as in the conventional cases. As a result, conventional problems such as difficulties in oral administration, the large size of carrier molecules in general, or technical problems in bond strength and affinity with the drug molecules can be resolved. Furthermore, it is possible to realize a drug delivery system which is easy to put into practical application. [0077] In the above first embodiment, regarding both the forskolin derivatives A and B, the three-dimensional structure is forcibly altered so as to crosslink the oxygen atom bonded to C 9 and the carbon atom bonded to C 13 . However, the types of atoms to be crosslinked are not limited to the above examples; and other atoms may be selected to be crosslinked. Moreover, by not performing crosslinking, but by simply changing an atom or a molecule for modifying the side chain, whether the relevant derivative is magnetic or not may be determined. [0078] Moreover, in the above first embodiment, forskolin is used as an organic compound for description. However, the type of organic compound to be used is not limited to this, and other organic compounds may be used. Hereunder is a description of, as another organic compound, a composition effective in treatments of male erectile dysfunction, more specifically, a composition inhibiting the activity of phosphodiesterase 5 (PDE 5), which hereinafter will be referred to as “PDE 5 inhibitor”. Drugs having this PDE 5 inhibitor as an active ingredient are used as remedies for male erectile dysfunction such as so-called Viagra®. [0079] FIG. 7A is a diagram of a basic molecular structural model of PDE 5 inhibitor with a standard composition and FIG. 7B shows a three-dimensional molecular structure and spin-charge density distribution of the PDE 5 inhibitor with a standard composition that are obtained by a computer simulation in the abovementioned drug design method. On the other hand, FIG. SA is a diagram of a basic molecular structural model of a PDE 5 inhibitor derivative derived by subjecting the PDE 5 inhibitor with a standard composition to side chain modifications. FIG. 8B shows a three-dimensional molecular structure and spin-charge density distribution of the PDE 5 inhibitor derivative obtained by the abovementioned computer simulation. In FIG. 8B , the regions 20 to 23 show upward spin-charge densities, and the regions 24 to 26 show downward spin-charge densities. Therefore, the PDE 5 inhibitor derivative is a ferrimagnetic body where the upward spin states 20 ′ to 23 ′ and the downward spin states 24 ′ to 26 ′ coexist as shown in FIG. 8A . [0080] That is, as shown in these FIGS. 7 and 8 , although the PDE 5 inhibitor with a standard composition is not magnetic, the PDE 5 inhibitor derivative which is generated by side chain modification is confirmed to be magnetic. Therefore, it has been found that as a result of using a therapeutic agent for male erectile dysfunction, which has such a magnetic PDE 5 inhibitor derivative as an active ingredient, pharmacological effects of the drug can be brought out specifically in the target site and the occurrence of side effects due to the combined use with the nitro preparations can be suppressed. Second Embodiment [0081] Next, a second embodiment is described using an inorganic compound, more specifically, cisplatin as an anticancer agent. Cisplatin is a metal complex (platinum complex) and classified as a platinum preparation among the anticancer agents. [0082] FIG. 9 is a diagram of a basic molecular structural model of cisplatin with a standard composition. Using the computer simulation by the drug design method described in the first embodiment, this cisplatin with a standard composition is confirmed to be non-magnetic. On the other hand, FIG. 10A is a diagram of a basic molecular structural model of a cisplatin derivative (Cis-Pt-a3), which is derived by subjecting the cisplatin with a standard composition to side chain modifications. Additionally, FIG. 10B shows a three-dimensional molecular structure and spin-charge density distribution of the cisplatin derivative (Cis-Pt-a3) obtained by the abovementioned computer simulation. [0083] In FIG. 10B , the regions 30 to 32 show upward spin-charge densities. Therefore, the cisplatin derivative (Cis-Pt-a3) is found to be a ferromagnetic body where the upward spin states 30 ′ to 32 ′ exist as show in FIG. 10A . That is, using the computer simulation by the present drug design method, the cisplatin derivative (Cis-Pt-a3) is confirmed to be magnetic. Therefore, by using an anticancer agent, which has such a magnetic cisplatin derivative (Cis-Pt-a3) as an active ingredient, pharmacological effects of the drug can be brought out specifically in the cancer tissues and the occurrence of side effects can be suppressed. [0084] The stronger the magnetism of a drug, the more efficiently the drug can be guided to the target site, and thus, a greater increase in pharmacological effects and suppression of side effects can be expected. Accordingly, the present inventors carried out an analysis of magnetic strength for various cisplatin derivatives using the computer simulation by the present drug design method. The analytical results are described below. Since the magnetic strength is in a linear relationship with the spin-charge density, the spin-charge densities in various cisplatin derivatives are analyzed in the present embodiment. [0085] Firstly, as a reference, particles having a total number of 101 atoms and which were approximately 8□ on a side were cut out from a magnetite (Fe 3 O 4 ) crystal and were set as the molecular models, and after electronic states and structures were optimized by the above-mentioned computer simulation, the analysis of spin-charge densities was performed. Then, by adopting the spin-charge density of the abovementioned magnetite particles as the standard, the analysis of spin-charge densities for various cisplatin derivatives was similarly carried out. FIG. 16 shows operation screens displayed during processing corresponding to step 12 of the aforementioned computer simulation. FIG. 16 ( 1 ) shows the spin-charge density of the compared magnetite.  indicates that the spin-charge density is positive; and ∘ indicates that the spin-charge density is negative. FIG. 16 ( 2 ) shows the calculated spin-charge density. The type of magnetism is ferrimagnetic (positive spin-charge density) and the magnetic strength is 10% as compared to magnetite. [0086] Furthermore, in addition to the cisplatin derivatives, various derivatives where platinum (Pt) of the cisplatin derivatives was substituted by palladium (Pd), rhodium (Rh), iridium (Ir), gold (Au), nickel (Ni), silver (Ag), copper (Cu), or cobalt (Co) were similarly analyzed for their spin-charge densities. The derivatives generated by the substitution of platinum in the cisplatin derivatives with the abovementioned metal elements, as described above, are known to have effects in inhibiting the replication of DNA which is accompanied with the propagation of cancer cells, similarly to cisplatin or cisplatin derivatives. [0087] FIG. 11 shows the analytical results of spin-charge densities of various cisplatin derivatives and of various derivatives where platinum (Pt) of the cisplatin derivatives was substituted by palladium (Pd), rhodium (Rh), iridium (Ir), gold (Au), nickel (Ni), silver (Ag), copper (Cu), or cobalt (Co), when the spin-charge density of the magnetite particles was standardized to “1”. [0088] As shown in FIG. 11 , among the cisplatin derivatives, it was found that NK121 had approximately 60% of spin-charge density compared to that of the magnetite particles and is effective as a magnetic drug compared to other cisplatin derivatives. This cisplatin derivative NK121 is one which once managed to reach clinical development after a safety test. However, since the anticancer effect thereof was comparable to that of cisplatin, it was determined to have no merits surpassing cisplatin and the development thereof was suspended. Therefore, if this cisplatin derivative NK121 is taken and the guidance of the drug to the target site by means of a magnetic field is performed, drug effects would increase and side effects can also be suppressed to a large extent. FIG. 12 shows a diagram of a basic molecular structural model of the cisplatin derivative NK121. As shown in this diagram, the cisplatin derivative NK121 is a ferromagnetic body where the upward spin states 40 ′ to 42 ′ exist. [0089] Moreover, the derivatives where platinum (Pt) of the cisplatin derivatives was substituted by palladium (Pd) were also confirmed to have spin-charge densities to some extent and thus, were magnetic bodies. In addition, among the derivatives where platinum (Pt) of the cisplatin derivatives was substituted by rhodium (Rh), Cis-Rh-a3 was found to have approximately 50% of spin-charge density compared to that of the magnetite particles and was effective as a magnetic drug. Further, the derivatives where platinum (Pt) of the cisplatin derivatives was substituted by iridium (Ir) were confirmed to have considerably small spin-charge densities and not many effects as magnetic drugs. Additionally, the derivatives where platinum (Pt) of the cisplatin derivatives was substituted by gold (Au) were also confirmed to have spin-charge densities to some extent and were magnetic bodies. [0090] Moreover, the derivatives where platinum (Pt) of the cisplatin derivatives was substituted by nickel (Ni) generally had approximately 50% of spin-charge densities compared to those of the magnetite particles and were found to be effective as magnetic drugs. Additionally, the derivatives where platinum (Pt) of the cisplatin derivatives was substituted by silver (Ag) were also confirmed to have spin-charge densities to some extent and were magnetic bodies. In addition, the derivatives where platinum (Pt) of the cisplatin derivatives was substituted by copper (Cu) were also confirmed to have spin-charge densities to some extent and were magnetic bodies. Furthermore, it was found that the derivatives where platinum (Pt) of the cisplatin derivatives was substituted by cobalt (Co) had, among higher ones thereof, approximately 95% of spin-charge densities compared to those of the magnetite particles, and also, generally had considerably high spin-charge densities, and were highly effective as magnetic drugs. [0091] As described so far, according to the drug design method in the present embodiment, not only with the drugs comprising organic compounds but also with those comprising inorganic compounds, it is possible to analyze whether they are magnetic or not from molecular models thereof. Moreover, by examining drugs with high magnetic strength (that is, with high drug effects) in advance, it will become possible to design effective drugs with a considerably high efficiency. [0092] The above-described cisplatin derivatives and the derivatives where platinum of the cisplatin derivatives was substituted by other metal elements are cis geometric isomers. Such cis geometric isomers are used as anticancer agents since they have higher effects at inhibiting the replication of DNA which is accompanied with the propagation of cancer cells than those in trans geometric isomers. However, according to the drug design method in the present embodiment, targeted drugs can be analyzed whether they are magnetic or not, not only when they are cis geometric isomers of anticancer agents or the like, but also when they are the metal complexes composed of trans geometric isomers or when they are other inorganic compounds. Therefore, it is also possible to design magnetic drugs comprising the metal complexes composed of trans geometric isomers, or other inorganic compounds. [0093] Next is a description of a guidance system for guiding the abovementioned magnetic drug to a target site. This guidance system may be any system as long as it generates a magnetic field, and various forms of systems can be considered. For example, application of magnetic resonance imaging (MRI) is considered, and the MRI system may be configured so that a magnetic field is irradiated to the human body and the magnetic field is controlled so as to guide the drug to the target site. Moreover, for example, a magnetic material such as a magnet may be adhered onto the skin surface of the target site. As a result, the drug that has reached the vicinity of the target site is guided to the target site, and stays specifically at the target site, causing no side effects to other normal cells. According to the above guidance system, it is possible to selectively and specifically guide a magnetic drug to the target site. [0094] Furthermore, using the magnetism of the drugs administered in a body, it is also possible to examine the dynamics of the drugs in the body, for example, the amount of drugs accumulated in affected tissues such as cancer tissues. More specifically, using a magnetic drug as a tracer, the dynamics of the drug in the body are examined by tracing the magnetism generated from the drug with a magnetic detector. With such a magnetic detector, it is possible to examine the dynamics of drugs in the body such as the time taken for the drugs to reach the target sites after being administered in the body and thus, the present invention can not only contribute to research and development of drugs, but also determine an appropriate dose of an anticancer agent. Since there is a correlation between the accumulated amount (concentration) of a magnetic drug using the MRI and MRI images as described later, analysis of the MRI images makes it possible to find the accumulated state of a therapeutic drug in affected tissues and determine an appropriate dose. [0095] Furthermore, functional diagnostic imaging can be performed by utilizing the magnetism and pharmacological action of the drug administered into a body. More specifically, there is a drug (such as forskolin) that has a high affinity for proteins developed in a large amount in highly malignant cancer tissues (for example, proteins called “P-glycoprotein”). The amount of forskolin accumulated in cancer tissues can be examined by making the forskolin magnetic and administering the magnetic forskolin to a cancer patient. If the accumulated amount in the cancer tissues is large, it is possible to diagnose the cancer of the patient as highly malignant; or if the accumulated amount is small, it is possible to diagnose the cancer of the patient as benign. The diagnosis of cancer malignancy grading can be made with only MRI images without taking conventional measures such as biopsy or surgery. [0096] The same can be said for the case where affected tissues are not those of a cancer, but are those of diseases relating to receptors for neural mediators such as acetylcholine, serotonin, and dopamine in the brain. For example, the severity level of Alzheimer's dementia can be determined by examining, with MRI images of the patient's head, the dynamics of a magnetic drug which specifically binds with receptor proteins. [0097] It is known that when the cisplatin with a standard composition shown in FIG. 9 is administered in the body, the cisplatin is hydrolyzed by the hydrolysis process represented by the reactions 1 to 3 shown in FIG. 13 , and finally generates the hydrolysis of cisplatin [Pt(OH 2 ) 2 (dien)] 2+ . As mentioned above, the cisplatin with a standard composition shown in FIG. 9 is not magnetic. However, the present inventors discovered that, based on the present drug design method, this hydrolysate of cisplatin [Pt(OH 2 ) 2 (dien)] 2+ is magnetic. FIG. 14 shows a three-dimensional molecular structure and spin-charge density distribution of the cisplatin hydrolysate [Pt(OH 2 ) 2 (dien)] 2+ . As shown in this diagram, since the cisplatin hydrolysate [Pt(OH 2 ) 2 (dien)] 2+ has regions 50 and 51 with upward spin-charge densities, it is found to be a ferromagnetic body. [0098] Therefore, even with the cisplatin with a standard composition, since it is magnetic after being administered in the body, it can be guided to the target site by the abovementioned guidance system and it is also possible to examine the dynamics thereof in the body with a magnetic detector and find the amount of the drug accumulated in cancer tissues. [0099] FIG. 17 is a block diagram illustrating the principles of MRI. When the aforementioned magnetic drug is administered to a human body through, for example, oral administration, injection, or fluid administration, the human body is exposed to a magnetic field. The human body is exposed to radio waves of a specified frequency emitted from a transmission coil 170 . The atomic nuclei of the administered drug molecules resonate with the radio waves and the atomic nuclei themselves then emit radio waves. A reception coil 172 receives such radio waves and synthesizes them into MR images. As a result, the location and of the drug in the human body can be visually detected. [0100] In the tissues into which the drug has been absorbed, the atomic nuclei constituting the tissues and the atomic nuclei of the drug are in different conditions. Therefore, an MRI control unit 174 selects an appropriate frequency of radio waves to be emitted and analyzes an MR signal emitted by certain atomic nuclei. As a result, it is possible to differentiate a signal of the drug and a signal of the tissues and detect in which tissues the drug exists. [0101] FIG. 18 is a perspective view of the entire MRI system. Reference numeral 180 represents an examination table on which a test subject is placed and moved within a cylindrical magnet gantry 182 . The magnet gantry is equipped with a magnet field generation device and a coil(s) for MR signal detection. The magnetic field strength of the magnet gantry is previously set to 0.2, 0.5, 1.0, or 1.5 teslas (unit). By moving the test subject within the magnetic field, the dynamics of the administered drug in the body can be controlled in accordance with the movement of the magnetic field. [0102] Using the MRI as described above makes it possible to not only examine the dynamics of the magnetic compound in the body, but also guide the magnetic compound to a target position in the body. The magnetic compound can also be used as a contrast medium for the MRI. [0103] Other methods besides the MRI can be adopted. A breast cancer will be explained in detail below. A breast cancer is located in breasts. If the horizontal length, the vertical length, and the depth are determined in terms of the three dimension, the site of cancer tissues of a breast cancer can be identified. The site of the breast cancer is determined in advance by, for example, the MR or CT. [0104] Permanent magnets are tucked into an undergarment (brassiere) on the side where the cancer is located. After an anticancer agent is administered to a patient, she wears the undergarment equipped with the magnets. The anticancer agent is directly injected into the cancer tissues. For example, the anticancer agent is injected into an artery leading to the breasts or into the cancer tissues. Subsequently, the patient wears the brassiere equipped with the magnets in order to avoid diffusion of the anticancer agent from the cancer tissues to the entire body. [0105] Moreover, the following method may also be employed. An anticancer agent is administered intravenously. The intravenously administered anticancer agent is supplied to the heart, and further passes from the aorta via the internal thoracic artery to the rami mammarii, and then finally to the breasts. The respective branches are then made subject to a magnetic field, thereby guiding the anticancer agent there. Specifically speaking, the magnetic field is applied toward the root of the internal thoracic artery where the aorta branches into the internal thoracic artery, so that the anticancer agent will be guided to flow from the aorta to the internal thoracic artery. Regarding the magnetic field strength, it was found as a result of cell culture examinations that if the distance is short, the anticancer agent can be guided at 1 tesla (the strength used by MR). Two teslas would be enough for organs close to the skin, like in the case of a breast cancer. The magnetic field strength of the MR is normally about 1.5 teslas. Regarding the measurement sensitivity, sufficient measurement sensitivity was achieved with the condition of T1 weighted images as a result of animal experiments. [0106] Next, an example of administering a drug to an individual body and obtaining images with the MRI system will be explained. FIG. 19 shows an MRI image taken with the MRI system, wherein the MRI image of a 9-week-old female rat (ddy by Japan SIC) was taken after administration through subcutaneous injection of a solution in which a magnetic iron complex (Fe-salen) was dissolved in pyridine (concentration: 0.137 mol/litter). As compared to the MRI image before the administration of the iron complex pyridine solution, the contrast effect can be observed in gaps between the organs and along the abdominal lining in the MRI image after the administration. The region indicated with arrows shows the iron complex accumulated in gaps between small intestines. When the MRI images were taken, small magnets were pasted to the abdominal cavity of the rat. The magnet field strength was set to 1.5 teslas in the MRI analysis. [0107] Furthermore, FIG. 20 shows that an MRI image is dependent on the concentration of a drug. A group of samples shown on the left side is obtained by diluting a pyridine concentrate solution with water (double distilled water (DDW)), while a group of samples shown on the right side is obtained by diluting a pyridine iron complex saturated solution with pyridine. By changing the concentration of the iron complex in pyridine to, for example, ½ or 1/16 of the aforementioned concentration of the solution containing only pyridine, the MRI can detect changes in the concentration through images. Subsequently, when rat L6 cells were in 30% confluent state, Fe complex powder was sprinkled over a culture medium as much as required to enable visual observation of the Fe complex powder when being drawn to magnets. 48 hours later, the condition of the culture medium was photographed. [0108] FIG. 21 shows the state where a bar magnet is made to be in contact with a rectangular flask with the culture medium for the rat L6 cells. Next, FIG. 22 shows the calculation results of the number of cells by photographing the bottom face of the rectangular flask from its one end to the other end 48 hours later. Referring to FIG. 22 , “proximal to magnet” means within the projected area of the bottom of the rectangular flask in contact with the end face of the magnet, while “distal from magnet” means an area of the rectangular flask opposite the end face of the magnet. FIG. 22 shows that at the area proximal to the magnet, the iron complex is drawn to the magnet and the concentration of the iron complex increases accordingly, and the number of cells is extremely low, as compared to the area distal from the magnet, because of DNA inhibition effect of the iron complex. As a result, the magnetic drug and the system including the magnetic field generating means according to the present invention can concentrate the drug at the target affected part or tissues of an individual body [0109] Next, another example of a guidance system according to the present invention will be explained. In this guidance system, a pair of magnets 230 and 232 located opposite to each other in a direction of gravitational force is supported by a stand 234 and a clamp 235 , and a metal plate 236 is placed between the magnets as shown in FIG. 23 . A locally uniform and strong magnet field can be generated by placing the metal plate, particularly an iron plate, between the pair of magnets. [0110] In this guidance system, electromagnets can be placed instead of the above-described magnets, so that the magnetic force to be generated can be made variable. Furthermore, a pair of magnetic force generating means may be designed to be movable in X, Y, and Z directions so that the magnetic force generating means can be moved to the target position of the individual body on the table. [0111] The drug can be concentrated on the target tissues by placing the tissues of the individual body in this area of the magnetic field. The aforementioned metal complex (drug concentration: 5 mg/ml (15 mM)) was administered intravenously to a mouse (weight: approximately 30 g), the abdominal cavity of the mouse was opened, and the mouse was then placed on the iron plate so that its right kidney was positioned between the pair of magnets. [0112] The magnets used were neodymium permanent magnets made by Shin-Etsu Chemical Co., Ltd. (product number: N50; residual magnetic flux density: 1.39-1.44 T). The magnetic field then applied to the right kidney was approximately 0.3 (T) and the magnetic field applied to the left kidney was approximately 1/10 of that for the right kidney. The magnetic field was applied to the mouse's right kidney; and 10 minutes later, the SNR of the right kidney as well as the left kidney and another kidney (control) to which no magnetic field was applied was measured in T1 mode and T2 mode, using the MRI system. As a result, it was confirmed as shown in FIG. 24 that a larger amount of the drug could be held in the tissues of the right kidney (RT), to which the magnetic field was applied, than in the left kidney (LT) or the control.
It is intended to provide a drug delivery system which makes it possible to solve the existing technical problems and is easily usable in practice. A drug, which comprises an organic compound or an inorganic compound and has been magnetized by modifying a side chain and/or crosslinking side chains, is induced by a magnetic force into target tissues or an affected part.
0
CROSS-REFERENCE TO RELATED APPLICATION(S) This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 60/447,984, filed on Feb. 15, 2003, which is incorporated herein by reference. FIELD OF THE INVENTION The present invention relates to an automated control system for operating a drawworks or similar hoisting means during a back reaming operation. BACKGROUND OF THE INVENTION In the petroleum industry, the apparatus and machinery used to drill wells is commonly known as a drilling rig or a rig. On these rigs are means of rotating the drill pipe, the most popular and successful of which is a device known as a top drive system. The popularity and proliferation of top drive systems within the oilfield has greatly enhanced the capability of the industry's drillers and operators to handle drill pipe operations in safe and beneficial manners. One such operation is “back reaming” wherein the operator hoists a drill pipe out of a borehole while simultaneous pumping drilling mud and rotating the drill pipe, thus avoiding the build-up of frictional forces between the drill pipe and the borehole that may lead to the drill pipe being jammed in the borehole. Until recently this back-reaming process has been done either completely manually or has involved the use of complicated controls within the hoisting equipment. For example, in the manual process, the operator engages a hoisting means by engaging a clutch and then manually manipulating a hoisting throttle, either a hand or foot throttle, to slowly and carefully hoist the drill pipe out of the borehole. However, during this operation, the driller must simultaneously monitor the hookload, and the rotating torque or standpipe pressure (if using a downhole mud motor) for indications that the pipe is in danger of jamming in a lateral direction or a rotational direction, respectively. Alternatively, in another process, the operator may be required to operate a control system that is connected to the hoisting means. In such a system, upon a command from the operator, the control system activates the hoisting means to slowly hoist the pipe out of the borehole. However, the driller must still monitor the hookload, the rotating torque and/or the standpipe pressure for indications of that the drill pipe may be in danger of jamming in the borehole. In addition, a problem with both of these processes is that many hoisting systems cannot tolerate holding a drill pipe without movement for an extended period of time, a situation that can occur when a drill pipe does jam in the borehole. Thus, each of these processes relies on the operator's judgment to avoid equipment damage. Accordingly, a need exists for an improved control system that allows for greater control of the back reaming process while reducing operator burden. SUMMARY OF THE INVENTION The present invention is directed to a control system for the automated operation of a drawworks during a “back reaming” operation. In one embodiment the control system is connected to an operator control unit to allow a driller to enter maximum values to be reached during the reaming operation for one or more specified reaming parameters. During the reaming operation, the control system continuously monitors the specified reaming parameters and compares the measured values to the limits or maximum values input by the operator. When any of the maximum values are exceeded, a control signal is sent to the drawworks to reduce the speed of the hoisting. In another embodiment, the specified reaming parameters may be selected from any or all of the pull on the drill bit (POB), the rate of hoisting (ROH), and the drilling torque. In still another embodiment, the speed of hoisting is controlled by the application of a drawworks brake assembly. In one embodiment, the present invention is an automated method for controlling a back reaming operation of a drilling rig. The method includes providing a hoisting system that moves a drill pipe during a back reaming operation at a hoisting speed and a hoisting torque. The hoisting system includes at least one back reaming parameter sensor for measuring a corresponding at least one back reaming parameter. The method further includes comparing a predetermined value of the at least one back reaming parameter with the measured value for the at least one back reaming parameter; and initiating a braking assembly that resists the hoisting torque of the hoisting system when the measured value of the at least one back reaming parameter equals the predetermined value of the at least one back reaming parameter. In another embodiment, the present invention is an automated method for controlling a back reaming operation of a drilling rig. The method includes providing a drawworks system that moves a drill pipe during a back reaming operation at a hoisting speed and a hoisting torque. The hoisting system comprises at least one back reaming parameter sensor for measuring a corresponding at least one back reaming parameter. The method further includes providing an operator control unit that allows an operator to input a predetermined value of the at least one back reaming parameter therein; and providing a control system that compares the predetermined value of the at least one back reaming parameter with the measured value for the at least one back reaming parameter, wherein the control system initiates a braking assembly that resists the hoisting torque of the drawworks system when the measured value of the at least one back reaming parameter equals the predetermined value of the at least one back reaming parameter. In yet another embodiment, the present invention is a system that controls a back reaming operation of a drilling rig that includes a hoisting system that moves a drill pipe during a back reaming operation at a hoisting speed and a hoisting torque. The hoisting system comprises at least one back reaming parameter sensor for measuring a corresponding at least one back reaming parameter. An operator control unit allows an operator to input a predetermined value of the at least one back reaming parameter therein. A back reaming parameter sensor obtains the measured value of the at least one back reaming parameter. A control system monitors the at least one back reaming parameter. A braking assembly resists the hoisting torque of the drawworks system when the measured value of the at least one back reaming parameter equals the predetermined value of the at least one back reaming parameter. BRIEF DESCRIPTION OF THE DRAWINGS These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein: FIG. 1 is a schematic representation of a drilling rig and a drawworks/brake control system according to the present invention; FIG. 2 is a block diagram of the drawworks/brake control system of FIG. 1 including a signal flow diagram; and FIG. 3 is a schematic representation of the drawworks/brake control system of FIG. 1 . DETAILED DESCRIPTION OF THE INVENTION As shown in FIGS. 1-3 , the invention is directed to a drawworks/brake control system 110 (hereinafter “control system 110 ”) for the automated operation of a drawworks 50 or similar hoisting means during a “back reaming” (hereinafter “reaming”) operation. As shown in FIG. 1 , in one embodiment of the current invention the control system 110 is connected to an operator control unit 115 . A driller or operator enters into the control unit 115 maximum values to be reached during the reaming operation for one or more specified reaming parameters. For example, the reaming parameters may include any or all of the pull on the drill bit (POB), the rate of hoisting (ROH), and the drilling torque. The operator then initiates the reaming operation. During the reaming operation, the control system 110 continuously monitors the POB, ROH and/or the drilling torque through various sensors 90 , 100 and 104 , and compares the measured values to the limits or maximum values input by the operator. When any of the maximum values are exceeded, a brake assembly 70 is activated via a control signal 109 from the control system 110 to reduce the speed of the hoisting. In such an embodiment, the brake assembly 70 modulates the speed of hoisting during the reaming operation by applying a braking torque that resists the hoisting torque of the drawworks 50 so as to maintain the limits set by the operator for POB, ROH and/or the drilling torque. FIG. 1 shows a schematic representation of the control system 110 of the current invention interconnected to a conventional drilling rig. In the depicted embodiment, a derrick 10 supports, at an upper end thereof, a crown block 15 . A rope arrangement 17 connects the crown block 15 to a traveling block 20 , or load bearing part, for supporting a hook structure 25 . The hook structure 25 is connected to and supports a top drive assembly 12 , which in turn is connected to a drill string 13 . The drill string 13 includes one or more drill pipes and a drill bit 14 that produces a borehole 16 in a drilling operation upon rotation by the top drive assembly 12 . The drawworks 50 is then used to hoist the drill string 13 out of the borehole 16 during a reaming operation. The drawworks 50 is attached to a hoisting line 30 , that assists the drawworks 50 in hoisting the drill string 13 during the reaming operation. The hoisting line 30 is securely fixed at one end to the ground by means of a dead line 35 and a dead line anchor 40 . The other end of the hoisting line 30 forms a fast line 45 that is attached to the drawworks 50 . In the embodiment shown in FIG. 1 , the drawworks 50 includes one or more motor(s) 55 , such as an electrical, diesel or other appropriate motor, and a transmission 60 connected to a cylindrical rotatable drum 65 for wrapping and unwrapping the fast line 45 as required for operation of the associated crown block 15 and traveling block 20 during drilling and reaming operations. In such an embodiment, the rotatable drum 65 is also referred to as a winding drum or a hoisting drum. Although one embodiment of a hoist system is shown in FIG. 1 it should be understood that other hoist systems capable of controllably raising a drill pipe could be utilized with the automated reaming control system of the current invention. As shown in FIG. 1 , a plurality of positioning sensors, such as proximity switches 102 in the derrick 10 or an encoder 100 that is affixed to the drawworks drive shaft 85 , may be used to determine the position of the traveling block 20 for additional safety and control during the reaming process. In such an embodiment, an output control signal 107 or 105 , indicting the position of the traveling block 20 is sent from the proximity switches 102 or the encoder 100 , respectively, to the control system 110 . The actual speed and position of the traveling block 20 may then be used to ensure safe operation of the hoist during reaming. Although in one embodiment the positioning sensors are proximity switches 102 , it should be understood that other means for determining the position of the traveling block 20 could be utilized with the automated reaming control system of the current invention. Although any brake capable of automated control may be utilized in the current invention, as shown in FIG. 1 , the brake assembly 70 preferably includes a primary friction brake 80 , typically a band type brake or a caliper disk brake, an auxiliary brake 75 , such as an eddy current type brake or a friction plate brake, and an emergency brake 78 . The brake assembly 70 is connected to the drawworks 50 by a drive shaft 85 of the drawworks 50 . The brake assembly 70 is controlled by the control system 110 . Again, although any suitable actuator may be utilized in the current invention, typically the brake 70 of the current invention is actuated either hydraulically or pneumatically, using, for example, a pneumatic cylinder that is applied by rig air pressure that is modulated by control signals 109 issued by the control system 110 by way of, for example, an electronically controlled air valve. As discussed above, to provide reaming monitoring signals to the control system 110 , a number of sensors may be utilized in the current invention. In the embodiment depicted in FIG. 1 , a load sensing device 90 , such as a strain gage or a hydraulic load cell is affixed to the dead line 35 , and produces an output control signal 95 indicating the tension in the dead line 35 and consequently, the load carried by the traveling block 20 or POB. This POB measurement from the load sensing device 90 is provided sent from the strain gage 90 to the control system 110 . Various tension measuring devices may be employed to indicate the tension conditions on the line 35 . In one embodiment, as shown in FIG. 1 , the actual hook load or POB is calculated using the load sensing device 90 input in conjunction with the number of lines strung and a calibration factor. Alternatively, a conventional load cell, hydraulic tension transducers or other load measuring device may be associated with the derrick 10 to provide the output control signal 95 representative of the load carried by the traveling block 20 . Alternatively, or in addition, the system may also be provided with a sensor for monitoring the rate of hoisting. In such an embodiment, as shown in FIG. 1 , a measuring device, such as an encoder 100 , for example, is affixed to the drawworks drive shaft 85 . In such an embodiment, an output control signal 105 , representative of the speed of rotation of the rotatable drum 65 as the drum 65 rotates to pull in or pay out the fast line 45 and as the traveling block 20 rises or descends, is sent from the encoder 100 to the control system 110 . Using such an encoder, the frequency of the signal may be used to measure the velocity of the traveling block 20 movement, typically, by calculating the actual drum 65 speed and ultimately the traveling block 20 speed based on lines strung, the diameter of the drum 65 , the number of line wraps and the line size. Alternatively, the velocity of the traveling block 20 movement may be calculated from the change in the vertical position of the traveling block 20 . In such a system, the ROH can be calculated from the velocity of the traveling block 20 . In addition, the proximity switches 102 may be utilized to confirm the measurements taken by the encoder 100 . Finally, as shown in FIG. 1 , alternatively, or in addition, the drilling torque may be monitored. The drilling torque may be measured by sensing the torque on the top drive or rotary table, such as by a torque sensor 104 or as reported by a top drive motor drive 112 or a rotary table drive 113 . In such an embodiment, an output control signal 108 indicating of the drilling torque is sent from the torque sensor 104 or from the drive 112 or 113 to the control system 110 . Alternatively, the drilling torque can be obtained by measuring the standpipe pressure when a downhole drilling motor is used. Referring to FIGS. 1-3 , the control system 110 is in signal connection with the brake assembly 70 to provide brake control signals 109 , and continuously receives output control signals 95 , 105 , and 108 from the load sensing device 90 , the encoder 100 , and the torque sensor 104 , respectively, wherein each of the output control signals 95 , 105 , and 108 is an electrical, digital or other appropriate signal. The control system 110 is also in signal communication with an operator control unit 115 located on or near the derrick 10 such that the operator can provide appropriate maximum values for the specified reaming parameters to be monitored. Alternatively, a separate workstation (not shown), located, for example, in an equipment room on or near the derrick 10 , can be connected to the control system 110 to provide an additional user interface and configuration signals. In one embodiment, as depicted in FIG. 2 , the operator control center 115 or man-machine interface preferably includes an industrial processor driven monitor 160 wherein the operator or driller can set and control the specified reaming parameters. For example, the operator can enter the maximum values to be reached during the reaming operation for any or all of the pull on the drill bit (POB), the rate of hoisting (ROH), and the drilling torque. As shown in FIG. 2 , the control system 110 includes a programmable controller (the drawworks PC 155 ), such as a programmable logic controller, a single board computer or an equivalent, to which are input the measured reaming values from the various sensors, and the respective operator defined maximum values from the operator control center 115 . The programmable controller 155 then compares the values and outputs appropriate control signals to the braking system and the drawworks that and are interfaced between the drive system 120 using, for example, a serial communication connection 150 such as, for example, an optical linkage and/or hard-wired linkage. In the embodiment shown, two or more remote programmable controllers (PC) input/output (I/O) units 145 are used to control the brake assembly 70 (including, as shown in FIG. 2 any or all of the disc brake 80 , the parking brake 75 , and the emergency brake 78 ) of the drawworks 50 and the drawworks processor 155 , although any suitable interface may be used. A processor 160 is also connected to the control system 110 for providing input and output of the operator values, operating parameters and calculated values during the performance of various drilling rig operations. Although not necessary, the control system 110 may also be connected to the motor(s) 55 of the drawworks through the drive system 120 . The motor(s) 55 may be an alternating current (ac) motor or a direct current (dc) motor and the drive system 120 is an ac or a dc drive, respectively. The drive system 120 may further include, for example, a controller 125 , such as a programmable controller (PC) and one or more motor drives 130 connected to an ac bus 135 for providing control of the motor. As discussed above, and shown in FIG. 3 , the control system 110 of the current invention may includes an auto back reaming (ABR) mode that the operator initiates by engaging a drawworks clutch, i.e. a high 2 B or a low 2 A clutch. Engaging the clutch 2 A or 2 B while the ABR is enabled (such as while auto-drilling) commands the control system 110 to activate the drive system 120 and the brake assembly 70 . During operation in the ABR mode, the control system 110 senses when the operator activates either the low or high clutch control, which in turn activates low and high clutch solenoids 7 g or 7 e , respectively. Signals from the activated clutch solenoids 7 g or 7 e and/or pressure sensors 7 D on the low 2 A or a high 2 B are then communicated to the control system 110 CPU, which senses the operator's intent to back ream. Once the drawworks clutch 2 is engaged, the control system 110 calculates the amount of torque needed to be supplied from the drawworks motor(s) 55 , and utilizes an output signal 7 F to control the torque command selector 9 , which in turn outputs a torque input 120 C to the drawworks drive 120 . The drawworks motor(s) 55 in turn produces torque, which exceeds that required to hold the load of the traveling block 20 stationary. The starting torque is calculated as the static hookload plus the operator entered maximum POB value. The control system 110 then utilizes control signals from the various sensors 7 C to calculate and monitor the reaming parameters, and these values are compared versus the limits on those parameters input by the operator, to ensure that the back reaming operation is performed within the operator limits. If the measured values from the sensors match or exceed the limits input by the operator, the CPU sends a signal to the brake actuator, which in turn controls the braking system 70 to apply a torque to resist the hoisting torque of the drawworks motor(s) 55 and control the rate of hoisting of the drill string, to in turn maintain the limits input by the operator for ROH, POB, and/or the drilling torque. The CPU commands the braking system 70 to apply a torque that resists the hoisting torque of the drawworks motor(s) 55 such that the hoisting speed is reduced until the relevant maximum value is no longer exceeded, and then commands the brake actuator to reduce the resisting torque of the brake system 70 to allow the drawworks motor(s) 55 to increase the speed of hoisting. For example, if while hoisting and back reaming, the top drive motor torque exceeds the limit input by the operator for drilling torque due to a tight hole condition, the CPU commands the brake actuator to control the brake assembly 70 to apply the brake to reduce the rate of hoisting to allow the drill motor torque to decrease as it drills through the tight area more slowly. This is possible because of the smooth proportional control of the brake assembly 70 and its sufficient capacity to produce more torque than the drawworks motor(s) 55 provides in this mode. If stopping the drawworks motor(s) 55 completely is required to prevent the reaming system from exceeding one or more of the limits for the specified reaming parameters input by the operator, the control system 110 sends a torque command 7 F to the torque command selector 9 , which in turn sends a torque command 120 C from the drive system 120 to reduce the torque produced by the drawworks motor(s) 55 to zero. This prevents damage to the motor and allows safe operation. When the control system 110 is not in the ABR mode, the drawworks torque command will come from a manual hand or foot throttle, or an equivalent device. In an alternative embodiment other controls may be used by the operator to command hoisting torque while the braking system is still used for speed control of the hoisting. As described above, the control system continuously monitors specified back reaming parameters and compares the measured values to the limits or maximum values input by the operator for the specified back reaming parameters. When any of the maximum values are meet or exceeded, a control signal is sent to the drawworks to reduce the speed of the hoisting. However, although the above description has focused on the monitoring of specific back reaming parameters, measured by specific back reaming parameter sensors, the monitored back reaming parameters can be any one or any combination of: weight on bit, hoisting torque, hoisting speed, drilling mud flow, drilling mud pressure, and formation cutting condition of mud screens within the drilling mud. These back reaming parameters can be measured by back reaming parameter sensors including any one or any combination of: strain gauges, proximity sensors/switches, cameras, gyroscopes, encoders, and magnetic pick ups/switches. The preceding description has been presented with references to presently preferred embodiments of the invention. Persons skilled in the art and technology to which this invention pertains will appreciate that alterations and changes in the described structures and methods of operation can be practiced without meaningfully departing from the principle, spirit and scope of this invention, such as various changes in the size, shape, materials, components, circuit elements, wiring connections, as well as other details of the illustrated circuitry and construction. Accordingly, the foregoing description should not be read as pertaining only to the precise structures described and shown in the accompanying drawings, but rather should be read as consistent with and as support for the following claims, which are to have their fullest and fairest scope.
A system that controls a back reaming operation of a drilling rig is provided that includes a hoisting system that moves a drill pipe during a back reaming operation at a hoisting speed and a hoisting torque. The hoisting system comprises at least one back reaming parameter sensor for measuring a corresponding at least one back reaming parameter. An operator control unit allows an operator to input a predetermined value of the at least one back reaming parameter therein. A back reaming parameter sensor obtains the measured value of the at least one back reaming parameter. A control system monitors the at least one back reaming parameter. A braking assembly resists the hoisting torque of the drawworks system when the measured value of the at least one back reaming parameter equals the predetermined value of the at least one back reaming parameter.
4
CROSS-REFERENCE TO RELATED APPLICATION This application is a 35 U.S.C. §371 national stage application of PCT International Application No. PCT/SE2009/051354, filed on Nov. 30, 2009, the disclosure and content of which is incorporated by reference herein as if set forth in its entirety. The above-referenced PCT International Application was published in the English language as International Publication No. WO 2011/065879on Jun. 3, 2011. TECHNICAL FIELD The present invention relates generally to an arrangement in a device for use with a service involving play out of media, and a method for controlling play out of media. BACKGROUND Today's electronic devices evolve rapidly, especially portable electronic devices. One of the trends lately is that they are capable of providing or supporting a variety of multimedia or entertainment services, such as play out of audio and/or video. Some examples of such devices are mobile telephones, Personal Digital Assistants (PDAs), mp3-players, laptops and so on. Very often, the user of an electronic device and hence a service provided by it, starts utilising the service, e.g. listening to audio from a radio broadcast or an mp3 file using a headset connected to the electronic device, and then puts the device away in a pocket or bag. If the user is interrupted, he/she must then take out the device from the pocket or bag and manipulate it in order to stop the play out and remove the headset before being able to engage in another activity called for by the interruption. Assume the play out is an audio book, the user most probably does not want during further play out to just remove the headset not hearing what is being read and thus “losing” information before stopping the play out. Once the user wants to resume his/her use of the service, he/she must then manipulate the electronic device in order to start the play out again. In case the user has lost some information that is “recoverable”, e.g. by rewinding the audio file, the user may have to find the point in time in the play out sequence where he/she was interrupted. In case the user was listening to, e.g. a real time radio broadcast or podcast, the information is permanently lost. There is a problem with existing electronic devices concerning the ease of use of the device. The manipulation of the device in order to control it and the services provided by it may be cumbersome and constitute a source of irritation for the user. There is another problem, caused by the cumbersome use of the device, that information may be lost for the user of the device. SUMMARY It is an object of the invention to address at least some of the problems outlined above. In particular, it is an object of the invention to provide an arrangement in a device for use with a service involving play out of audio from a headset, and a method for controlling play out of audio from a headset connected to a user device. According to one aspect, an arrangement in a device for use with a service involving play out of audio from a headset is provided. The arrangement comprises an application for providing the play out of audio to a user of the device, and the application has at least two modes of operation including a first active mode and a second active mode. The first active mode corresponds to the headset being in full physical contact with the user and the second active mode corresponds to the headset being in less than full physical contact with the user. The detection of full physical contact of the headset with the user causes the application to be in the first active mode and detection of less than full physical contact of the headset with the user causes the application to switch to the second active mode. The first active mode entails full use and/or operation of the service and the second active mode entails modified use and/or operation of the service. Thereby, the modes can be adapted to the status of the physical contact of the headset with the user, thereby customizing the device to optimize the user experience of the use of the service. According to an embodiment of the arrangement, the first active mode corresponds to full operation of a microphone and speakers of said headset, and when the application switches to the second active mode, audio signals from the microphone of the headset are discarded so as to mute the microphone of the headset. According to another embodiment of the arrangement, the device is used for listening to a radio broadcast or podcast and the first active mode corresponds to playing the radio broadcast or podcast to the user in real time through speakers in the headset. The detection of less than full physical contact of the headset with the user causes the application to switch to the second active mode, wherein the radio broadcast or podcast is recorded in the device. Thereby, the user is able to recover any possible lost information due to the total or partial removal of headset. According to one example, a subsequent detection of full physical contact of the headset with the user causes the application to start a playback of the recorded radio broadcast or podcast from the point in time when less than full physical contact of the headset with the user was detected. According to another embodiment of the arrangement, the first active mode corresponds to operating speakers of the headset in stereo and the detection of less than full physical contact of the headset with the user causes the application to switch to the second active mode corresponding to operating speakers of the headset in mono. In this way, the play out of audio may be customized and/or optimized in dependence of the physical contact of the headset with the user so that the user may always experience the best possible play out of audio. In yet another embodiment, the first active mode corresponds to playing out audio from the headset using a first bitrate and/or a first compression scheme and the detection of less than full physical contact of the headset with the user causes the application to switch to the second active mode, wherein the audio is played out from a speaker in the device using a second bitrate and/or a second compression scheme. This is another possible way of customizing and/optimizing the play out of media in dependence of the physical contact of the headset with the user so that the user may always experience the best possible play out of audio. According to another aspect, a method for controlling play out of audio from a headset connected to a user device is provided. The method comprises detecting full physical contact of said headset with a user or less than full physical contact of the headset with a user. The the detection of full physical contact of the headset with the user causes an application in the user device to operate in a first active mode, which entails full use and/or operation of said play out of audio, and the detection of less than full physical contact of the headset with the user causes said application in the user device to operate in a second active mode, which entails modified use and/or operation of said play out of audio. According to an embodiment of the method, the first active mode corresponds to full operation of a microphone and speakers of said headset. When the application switches to the second active mode, audio signals from the microphone of the headset are discarded to as to mute the microphone of the headset. According to another embodiment of the method, the user device is used for listening to a radio broadcast and the first active mode corresponds to playing the radio broadcast to the user in real time through speakers in the headset. The detection of less than full physical contact of the headset with the user causes the application to switch to the second active mode, wherein the radio broadcast is recorded in the device. According to one example, a subsequent detection of full physical contact of the headset with the user causes the application to start a playback of the recorded radio broadcast from the point in time when less than full physical contact of the headset with the user was detected. In yet another embodiment of the method, the detection of full physical contact of the headset with the user causes the application to be in the first active mode corresponding to operating speakers of the headset in stereo. The detection of less than full physical contact of the headset with the user causes the application to switch to the second active mode corresponding to operating speakers of the headset in mono. According to one embodiment of the method, the detection of full physical contact of the headset with the user causes the application to operate in the first active mode corresponding to playing out audio from the headset using a first bitrate and/or a first compression scheme. The detection of less than full physical contact of the headset with the user causes the application to switch to the second active mode, wherein the audio is played out from a speaker in the device using a second bitrate and/or a second compression scheme. Further possible features and benefits of the invention will be explained in the detailed description below. BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described in more detail by means of preferred embodiments and with reference to the accompanying drawings, in which: FIG. 1 is a logical representation of an arrangement in a device for use with a service involving play out of media. FIG. 2 is a flowchart of a method for controlling play out of audio according to an embodiment. DETAILED DESCRIPTION Briefly described, an arrangement in a device for use with a service involving play out of media, and a method for controlling play out of media are provided. FIG. 1 illustrates a logical representation of an embodiment of an arrangement in a device 100 for use with a service involving play out of audio from a headset 140 . The arrangement in a device 100 comprises an application 110 for providing play out of audio to a user of the device 100 , wherein the application 110 has at least two modes of operation including a first active mode 111 and a second active mode 112 . The first active mode 111 corresponds to the headset 140 being in full physical contact with the user and the second active mode 112 corresponds to the headset 140 being in less than full physical contact with the user. The detection of full physical contact of the headset 140 with the user causes the application 110 to be in the first active mode 111 and the detection of less than full physical contact of the headset 140 with the user causes the application 110 to switch to the second active mode 112 . The first active mode 111 entails full use and/or operation of the service and the second active mode 112 entails modified use and/or operation of the service. The headset 140 may comprise one or two earpieces, wherein an earpiece comprises a speaker that emits sound when the application 110 plays out audio. In case the headset 140 comprises one earpiece, full physical contact of the headset 140 with the user corresponds to the earpiece being in full physical contact with the user, such as being inserted into the ear of the user. Less than full physical contact with the user corresponds to the earpiece being removed from the ear of the user. In case the headset 140 comprises two earpieces, full physical contact of the headset 140 with the user corresponds to both earpieces being in full physical contact with the user, such as being inserted into the ears of the user. Less than full physical contact corresponds to at least one of the earpieces being removed from the ears of the user. By configuring the application 110 with at least two active modes 111 and 112 associated with the physical contact of the headset 140 with the user, it is possible to switch modes depending on the status of the headset 140 . As the headset 140 is in full physical contact, full use and/or operation of the service is provided. As the user removes the earphone(s) from his/her ear(s), the mode of operation of the application 110 is changed to the second active mode 112 , which entails modified use and/or operation of the service. The second modified use and/or operation of the service may entail different features, depending on the current service the user is utilising. FIG. 1 also discloses an Operation Unit 120 . In the logical representation of the device 100 illustrated in FIG. 1 , the application 110 controls the operation unit 120 so as to control the function or operation of the device and/or service. It shall be noted that the operation unit 120 does not necessarily have to be implemented as a separate unit, but may be implemented in the application 110 . FIG. 2 is a flowchart of a method for controlling play out of audio according to one exemplary embodiment. As described above, the full or less than full physical contact of the headset 140 with a user thereof is associated with two separate active modes of operation of the application 110 , i.e. the first active mode 111 , 220 and the second active mode 112 , 240 . The detection of change in physical contact 210 , 230 of the headset 140 with a user thereof will cause a change of active mode in the application controlling the service being in use. When a use of a service is commenced, it is first detected 210 if the headset 140 is in full physical contact with the user of the device 100 that is used. If the headset 140 is in full physical contact with the user, the application 110 will operate in the first active mode 111 , 220 . If the headset 140 is in less than full physical contact with the user, the application 110 will operate in the second active mode 112 , 240 . Thereafter, any detection of a change in physical contact 230 of the headset 140 with the user will cause the application 110 to change operation mode. In one embodiment, the first active mode 111 , 220 corresponds to full operation of a microphone and speakers of the headset 140 , and when the application switches to the second active mode 112 , 240 , audio signals from the microphone of the headset 140 are discarded to as to mute the microphone of the headset 140 . Assume the user is engaged in a conference call involving at least two other persons or participants. The user is using a headset 140 connected to a laptop or a mobile phone, constituting the device 100 described above, for this conference call. Also assume the headset 140 has two earpieces, both being inserted in the ears of the user. The user is interrupted by another person needing the user's attention. When detecting that one earpiece is removed, the application 110 in the laptop or mobile phone controlling the service switches operation mode from the first active mode 111 , 220 to the second active mode 112 , 240 . In the second active mode 112 , 240 , audio signals from the microphone of the headset 140 are discarded so as to mute the microphone of the headset 140 . This means that the user may still be able to hear the other persons talking, not missing out on anything being said, but also his/her microphone is muted so that the user may speak freely to the interrupting person without the other participants in the conference call being able to hear what the user is saying. When detecting that the currently removed earpiece of the headset 140 is re-inserted in the user's ear, the application 110 switches operation mode to the first active mode 111 , 220 , corresponding to regained full operation of the microphone and speakers of the headset 140 so that the other participants may again hear what the user is saying. Of course, in the example above, the headset 140 may comprise just one earpiece and the removal of it from the ear of the user will in the same manner mute the microphone of the headset 140 . According to another embodiment, the device 100 is used for listening to a radio broadcast or podcast and the first active mode 111 , 220 corresponds to playing the radio broadcast or podcast to the user in real time through speaker(s) in the headset 140 . The detection of less than full physical contact 210 , 230 of the headset 140 with the user causes the application 110 to switch to the second active mode 112 , 240 , wherein the radio broadcast or podcast is being recorded in the device 100 . This embodiment improves the controlling and manipulation of the electronic device 100 , and thus improves user experience. Also, it is ensured that the user will not lose any information being consumed by listening to the broadcast. From the point in time when less than full physical contact is detected 210 , 230 , the broadcast information is recorded in the device, as the application 110 switches to the second active mode 112 , 240 , ensuring the user will not lose any information. A subsequent detection of full physical contact 230 of the headset 140 with the user causes the application 110 to start a playback of the recorded radio broadcast or podcast from the point in time when less than full physical contact of the headset 140 with said user was detected and the recording was commenced. Although the playback is commenced, the radio broadcast or podcast is still being recorded until the current broadcast has ended. Should the user again remove the earpiece(s) so that less than full physical contact is detected, the playback will pause and be resumed when the full physical contact is again detected. In yet another embodiment, the first active mode 111 , 220 corresponds to operating speakers of the headset 140 in stereo, i.e. the audio information in one speaker is different from that in the other speaker. The detection of less than full physical contact 210 , 230 of the headset 140 with the user causes the application 110 to switch to the second active mode 112 , 240 corresponding to operating the speakers of the headset 140 in mono, such that the audio information is the same in both speakers. Thereby, no audio information will be missed by the user. It may be the case that the play out should not be stopped, paused or recorded due to less than full physical contact of the headset 140 with the user thereof. Assume a user is listening to music using a headset 140 with two earpieces. When in full physical contact with the user thereof, corresponding to both earpieces being inserted into the ears of the user, the music is played out in stereo. As the user removes at least one of the earpieces of the headset 140 from his or her ear, the operation mode of the application 110 is switched to the second active mode 112 , 240 , entailing playing out the music in mono. This ensures that the user may still listen to the music without parts of it being lost due to the play out of those parts in the earpiece that has been removed. The play out in mono can be done in both earpieces regardless of which one is being removed. The play out in mono may also be performed only in the earpiece still being inserted in the ear of the user. As the user re-inserts the removed earpiece into his or her ear, the operation mode of the application 110 is switched to the first active mode 111 , 220 and the play out of the music is again performed in stereo. According to one embodiment, the first active mode 111 , 220 corresponds to playing out audio from the headset 140 using a first bitrate and/or a first compression scheme and the detection of less than full physical contact 210 , 230 of the headset 140 with the user causes the application 110 to switch to the second active mode 112 , 240 , wherein the audio is played out from a speaker in the device 100 using a second bitrate and/or a second compression scheme. Different speakers typically require quite different bitrates and/or compression schemes in order to play out audio. The better quality of the speaker or speakers, the higher bitrate and/or compression scheme may be required in order to make use of the speaker's full potential. For example, a user is using a headset 140 for listening to music from an mp3-player or a mobile telephone, which also comprises a speaker in its housing. The application 110 is operating in the first active mode 111 , 220 playing out the audio using a first bitrate and/or a first compression scheme. The speakers of the headset 140 are usually of a good quality and may require or be able to reproduce audio using a high bitrate and/or certain compression scheme. As the user removes the headset 140 , the application 110 switches to the second active operation mode 112 , 240 . In this example, the second active mode 112 , 240 entails playing out the audio from the speaker in the housing of the device 100 , such as an mp3-player or a mobile telephone, using a second bitrate and/or a second compression scheme. Assume the speaker in the device 100 is of somewhat mediocre quality, or at least less than the quality of the speakers of the headset 140 . Then the speaker of the device 100 cannot reproduce the audio with the same quality as the speakers of the headset 140 . Then, it might be the case that the speaker of the device 100 may operate better with another bitrate and/or compression scheme than the speakers of the headset 140 . By this embodiment, it is possible to make better use of the resources available in the device and to ensure that the operating speaker(s) is/are provided with the optimal available bitrate and/or compression scheme depending on the quality and characteristics of the speaker(s). It shall be noted that the design of the headset lies outside of the invention. It may be designed as to have insertable earpieces, it may alternatively be designed as to have cushions surrounding the ear(s) or any other design or configuration so that physical contact of the headset with a user is detectable. While the invention has been described with reference to specific exemplary embodiments, the description is generally only intended to illustrate the inventive concept and should not be taken as limiting the scope of the invention. The present invention is defined by the appended claims.
Arrangements in a device for use with a service involving play out of audio from a headset are provided. The arrangements include an application for providing the play out of audio to a user of the device. The application has at least two modes of operation including first and second active modes. In the first active mode, the headset is in full physical contact with the user. In the second active mode, the headset may not be in full physical contact with the user. The application is configured to switch between the first and second modes of operation based on whether the headset is detected to be in full physical contact with the user. In the first active mode, the user is entitled to full use and/or operation of the service. In the second active mode, the user is entitled to modified use and/or operation of the service. Related methods are also provided.
7
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention pertains to the field of urethane catalysts. More particularly, this invention relates to the use of certain amine derivatives as a urethane catalyst. 2. Description of the Prior Art The use of a catalyst in preparing polyurethanes by the reaction of a polyisocyanate, a polyol and perhaps other ingredients is known. The catalyst is employed to promote at least two, and sometimes three major reactions that must proceed simultaneously and competitively at balanced rates during the process in order to provide polyurethanes with the desired physical characteristics. One reaction is a chain-extending isocyanate-hydroxyl reaction by which a hydroxyl-containing molecule is reacted with an isocyanate-containing molecule to form a urethane. This increases the viscosity of the mixture and provides a polyurethane containing secondary nitrogen atom in the urethane groups. A second reaction is a cross-linking isocyanate urethane reaction by which an isocyanate-containing molecule reacts with a urethane group containing a secondary nitrogen atom. The third reaction which may be involved is an isocyanate-water reaction by which an isocyanate-terminated molecule is extended and by which carbon dioxide is generated to blow or assist in the blowing of foam. This third reaction is not essential if an extraneous blowing agent, such as a halogenated, normally liquid hydrocarbon, carbon dioxide, etc., is employed, but is essential if all or even part of the gas for foam generation is to be generated by this in situ reaction (e.g. in the preparation of "one-shot" flexible polyurethane foams). The reactions must proceed simultaneously at optimum balanced rates relative to each other in order to obtain a good foam structure. If carbon dioxide evolution is too rapid in comparison with chain extension, the foam will collapse. If the chain extension is too rapid in comparison with carbon dioxide evolution, foam rise will be restricted, resulting in a high density foam with a high percentage of poorly defined cells. The foam will not be stable in the absence of adequate crosslinking. It has long been known that tertiary amines are effective for catalyzing the second crosslinking reaction. Typical amines of this type are found in U.S. Pat. Nos. 4,012,445; 3,925,268; 3,786,005; 4,011,223; 4,048,107; 4,038,210; 4,033,911; 4,026,840; 4,022,720 and 3,912,689. However, many amines of this class have a strong amine odor which is carried over to the polyurethane foam. In still other cases, some tertiary amines impart a color to the product foam known as "pinking" and/or cause or fail to prevent undue foam shrinkage. In addition to problems of odor, pinking, etc., other tertiary amines suffer still further deficiencies. For example, in some instances the compounds are relatively high in volatility leading to obvious safety problems. In addition, some catalysts of this type do not provide sufficient delay in foaming, which delay is particularly desirable in molding applications to allow sufficient time to situate the preform mix in the mold. Yet other catalysts, while meeting specifications in this area do not yield foams with a desirable tack-free time. In addition, some catalysts of this type are solids causing handling problems. Lastly, in many cases blends of catalysts containing different tertiary amine groups must be utilized in order to achieve the desired balance between gelling and flowing of foams. It would therefore be a substantial advance in the art if a new class of amine catalysts were discovered which overcome the just enumerated disadvantages of the prior art. SUMMARY OF THE INVENTION A new class of amine compounds have been discovered which have been found useful as polyurethane catalysts. Said amines fall within the following structural formula: ##STR2## wherein R 1 and R are lower alkyl and x=0-2. DESCRIPTION OF THE PREFERRED EMBODIMENTS The compounds useful here may be prepared by resort to a wide variety of synthetic techniques. However, preferably the appropriate alkoxy amine is condensed with formaldehyde and a lower alkanol. Thereafter, the intermediate derivatives are then hydrogenated over an appropriate catalyst such as nickel. Preferably R 1 and R contain 4 carbon atoms, more preferably are methyl or ethyl and most preferably are methyl. The compounds here possess a number of useful characteristics making them exceptionally attractive as polyurethane catalysts. For example, they have rapid catalytic activity in the polyurethane foam area. In addition, the compounds here are also relatively non-volatile and possess little, if any odor. Also, the compounds do not cause excessive pinking, so often observed when other tertiary amine catalysts are employed, particularly when polyester polyols are used to make urethanes. The catalysts of the invention are particularly desirable in foaming urethanes in that they provide a sufficient delay in the foaming operation to aid in processing. Yet the catalysts also give good foams with desirable tack-free times. This delay time is particularly desirable in molding applications to allow sufficient time to situate the prefoam mix in the mold. In addition, the compounds are easily prepared as typically described above, and are relatively inexpensive. It has also been noted that the compounds described here in addition to being almost odor-free can be used to prepare foams such as polyester-based urethane foams without noting any substantial shrinkage in the foam so made. Lastly, they may be used as the sole catalyst source without resort to a blend of amine catalysts. Thus, the desired balance between foam gelling and flowing is obtained without resort to a catalyst blend, and a good reaction profile is obtained with sole use of the catalysts of the invention. To prepare polyurethanes using the catalysst here, any aromatic polyisocyanate may be used. Typical aromatic polyisocyanates include m-phenylene diisocyanate, p-phenylene diisocyanate, polymethylene polyphenylisocyanate, 2,4-toluene diisocyanate, 2,6-tolulene diisocyanate, dianisidine diiso cyanate, bitolylene diisocyanate, naphthalene-1,4-diisocyanate, xylylene-1,4-diisocyanate, xylylene-1,3-diisocyanate, bis(4-isocyanatophenyl) methane, bis(3-methyl-4-isocyanatophenyl) methane, bis(3-methyl-4-isocyanatophenyl) methane, and 4,4'-diphenylpropane diisocyanate. Greatly preferred aromatic polyisocyanates used in the practice of the invention are 2,4- and 2,6-toluene diisocyanates and methylene-bridged polyphenyl polyisocyanate mixtures which have a functionality of from about 2 to about 4. These latter isocyanate compounds are generally produced by the phosgenation of corresponding methylene bridged polyphenyl polyamines, which are conventionally produced by the reaction of formaldehyde and primary aromatic amines, such as aniline, in the presence of hydrochloric acid and/or other acidic catalysts. Known processes for preparing polyamines and corresponding methylene-bridged polyphenyl polyisocyanates therefrom are described in the literature and in many patents, for example, U.S. Pat. Nos. 2,683,730; 2,950,263; 3,012,008; 3,344,162 and 3,362,979. Most preferred methylene-bridged polyphenyl polyisocyanate mixtures used here contain about 20 to about 100 weight percent methylene diphenyldiisocyanate isomers, with the remainder being polymethylene polyphenyl polyisocyanates having higher functionalities and higher molecular weights. Typical of these are polyphenyl polyisocyanate mixtures containing about 20 to 100 weight percent methylene diphenyldiisocyanate isomers, of which 20 to about 95 weight percent thereof is the 4,4'-isomer with the remainder being polymethylene polyphenyl polyisocyanates of higher molecular weight and functionality that have an average functionality of from about 2.1 to about 3.5. These isocyanate mixtures are known, commercially available materials and can be prepared by the process described in U.S. Pat. No. 3,362,979, issued Jan. 9, 1968 to Floyd E. Bentley. The hydroxyl-containing polyol component which reacts with the isocyanate may suitably be a polyester polyol or a polyether polyol having a hydroxyl number ranging from about 700 to about 25, or lower. When it is desired to provide a flexible foam, the hydroxyl number is preferably in the range from about 25 to 60. For rigid foams, the hydroxyl number is preferably in the range from 350 to 700. Semi-rigid foams of a desired flexibility are provided when the hydroxyl number is intermediate to the ranges just given. When the polyol is a polyester, it is preferable to use as the polyester, a resin having a relatively high hydroxyl value and a relatively low acid value made from the reaction of a polycarboxylic acid with a polyhydric alcohol. The acid component of the polyester is preferably of the dibasic or polybasic type and is usually free of reactive unsaturation, such as ethylenic groups or acetylenic groups. The unsaturation, such as occurs in the rings of such aromatic acids as phthalic acid, terephthalic acid, isophthalic acid, or the like, is non-ethylenic and non-reactive. Thus, aromatic acids may be employed for the acid component. Aliphatic acids, such as succinic acid, adipic acid, sebabic acid, azelaic acid, etc., may also be employed and are preferred. The alcohol component for the polyester should preferably contain a plurality of hydroxyl groups and is preferably an aliphatic alcohol, such as ethylene glycol, glycerol, pentaerthritol, trimethylolethane, trimethylolpropane, mannitol, sorbitol, or methyl glucoside. Mixtures of two or more of the above identified alcohols may be employed also if desired. When a flexible urethane foam is desired, the polyol should preferably have an average functionality of from about 2 to about 4 and a molecular weight of from about 2,000 to about 6,000. For rigid foams, the functionality of the polyol component is preferably from about 4 to about 8. When the hydroxyl-containing component is a polyether polyol for use in flexible polyurethane foam, the polyol may be an alkylene oxide adduct of a polyhydric alcohol with a functionality of from about 2 to about 4. The alkylene oxide may suitably be ethylene oxide, propylene oxide, or 1,2-butylene oxide, or a mixture of some or all of these. The polyol will suitably have a molecular weight within the range of from about 2,000 to about 7,000. For flexible polyether polyurethane foams, the alkylene oxide is preferably propylene oxide or a mixture of propylene oxide and ethylene oxide. For rigid polyether polyurethane foams, the polyol should have a functionality of from about 4 to about 8 and a molecular weight of from about 300 to about 1,200. Polyols for rigid polyether polyurethane foams may be made in various ways including the addition of an alkylene oxide as above to a polyhydric alcohol with a functionality of from 4 to 8. These polyols may also be, for example, Mannich condensation products of a phenol, an alkanolamine, and formaldehyde, which Mannich condensation product is then reacted with an alkylene oxide (see U.S. Pat. No. 3,297,597). The amount of hydroxyl-containing polyol compound to be used relative to the isocyanate compound in both polyester and polyether foams normally should be such that the isocyanate groups are present in at least an equivalent amount, and preferably, in slight excess, compared with the free hydroxyl groups. Preferably, the ingredients will be proportioned so as to provide from about 1.05 to about 1.5 mol equivalents of isocyanate groups per mol equivalent of hydroxyl groups. However, for certain shock absorbing foams we have found that by using the catalyst of our invention the mol equivalents of isocyanate to hydroxyl groups can be as low as 0.4. When water is used, the amount of water, based on the hydroxyl compound, is suitably within the range of about 0.05 mol per mol equivalent of hydroxy compound. It is within the scope of the present invention to utilize an extraneously added inert blowing agent such as a gas or gas-producing material. For example, halogenated low-boiling hydrocarbons, such as trichloromonofluoromethane and methylene chloride, carbon dioxide, nitrogen, etc., may be used. The inert blowing agent reduces the amount of excess isocyanate and water that is required in preparing flexible urethane foam. For a rigid foam, the use of water is often avoided and the extraneous blowing agent is used exclusively. Selection of the proper blowing agent is well within the knowledge of those skilled in the art. See for example U.S. Pat. No. 3,072,082. The catalysts discovered here which are useful in the preparation of rigid or flexible polyester or polyether polyurethane foams, based on the combined weight of the hydroxyl-containing compound and polyisocyanate are employed in an amount of from about 0.05 to about 4.0 weight percent. More often, the amount of catalyst used is 0.1-1.0 weight percent. Most preferably, the catalysts here are employed to prepare packaging foams due to excellent gel properties. The catalysts of this invention may be used either alone or in a mixture with one or more other catalysts such as tertiary amines or with an organic tin compound or other polyurethane catalysts. The organic tin compound, particularly useful in making flexible foams may suitably be a stannous or stannic compound, such as a stannous salt of a carboxylic acid, a trialkyltin oxide, a dialkyltin dihalide, a dialkyltin oxide, etc., wherein the organic groups of the organic portion of the tin compound are hydrocarbon groups containing from 1 to 8 carbon atoms. For example, dibutyltin dilaurate, dibutyltin diacetate, diethyltin diacetate, dihexyltin diacetate, di-2-ethylhexyltin oxide, dioctyltin dioxide, stannous octoate, stannous oleate, etc., or a mixture thereof, may be used. Such other tertiary amines include trialkylamines (e.g. trimethylamine, triethylamine), heterocyclic amines, such as N-alkylmorpholines (e.g., N-methylmorpholine, N-ethylmorpholine, etc.), 1,4-dimethylpiperazine, triethylene-diamine, etc., and aliphatic polyamines, such as N,N,N'N'-tetramethyl-1,3-butanediamine. Conventional formulation ingredients are also employed such as, for example, foam stabilizers, also known as silicone oils or emulsifiers. The foam stabilizer may be an organic silane or siloxane. For example, compounds may be used having the formula: RSi[O--(R.sub.2 SiO).sub.n --(oxyalkylene).sub.m R].sub.3 wherein R is an alkyl group containing from 1 to 4 carbon atoms; n is an integer of from 4 to 8; m is an integer of from 20 to 40; and the oxyalkylene groups are derived from propylene oxide and ethylene oxide. See, for example, U.S. Pat. No. 3,194,773. In preparing a flexible foam, the ingredients may be simultaneously, intimately mixed with each other by the so-called "one-shot" method to provide a foam by a one-step process. In this instance, water should comprise at least a part (e.g., 10% to 100%) of the blowing agent. The foregoing methods are known to those skilled in the art, as evidenced by the following publication: duPont Foam Bulletin, "Evaluation of Some Polyols in One-Shot Resilient Foams", Mar. 22, 1960. When it is desired to prepare rigid foams, the "one-shot" method or the so-called "quasi-prepolymer method" is employed, wherein the hydroxyl-containing component preferably contains from about 4 to 8 reactive hydroxyl groups, on the average, per molecule. In accordance with the "quasi-prepolymer method", a portion of the hydroxyl-containing component is reacted in the absence of a catalyst with the polyisocyanate component in proportions so as to provide from about 20 percent to about 40 percent of free isocyanato groups in the reaction product, based on the polyol. To prepare a foam, the remaining portion of the polyol is added and the two components are allowed to react in the presence of catalytic systems such as those discussed above and other appropriate additives, such as blowing agents, foam stabilizing agents, fire retardants, etc. The blowing agent (e.g., a halogenated lower aliphatic hydrocarbon), the foam-stabilizing agent, the fire retardant, etc., may be added to either the prepolymer or remaining polyol, or both, prior to the mixing of the component, whereby at the end of the reaction a rigid polyurethane foam is provided. Urethane elasomers and coatings may be prepared also by known techniques in accordance with the present invention wherein a tertiary amine of this invention is used as a catalyst. See, for example, duPont Bulletin PB-2, by Remington and Lorenz, entitled "The Chemistry of Urethane Coatings". The invention will be illustrated further with respect to the following specific examples, which are given by way of illustration and not as limitations on the scope of this invention. EXAMPLE I Preparation of the Catalyst In a liter flask was placed 1500 ml of methanol and 198 grams of paraformaldehyde. To this slurry were slowly added 399 grams of methoxyethoxypropylamine. The reaction exothermed to 57° C. It was allowed to stir for 21/2 hours and then to stand overnight. The reaction mixture was then charged to a pressure clave along with 100 grams of a nickel catalyst. The clave was pressurized to 100 psig with hydrogen then heated to 100° C. The hydrogen pressure was increased to 1000 psig and held until the hydrogen uptake had stopped, after about 2 hours. The reaction was cooled, filtered through a filter aid and the methanol removed under vacuum. It was then distilled at 15 mm Hg with the product boiling from 80°-85° C. The product was N,N-dimethyl-3-methoxyethoxypropylamine. EXAMPLE II The following gives a typical foam formulation and reaction profile using the catalyst of Example I to prepare polyester-based urethane foams. As can be seen from Table I less catalyst of this invention is required versus two widely used commercial catalysts. TABLE I______________________________________ II III IV______________________________________FOMREZ® 50.sup.1 100 100 100Silicone L-532.sup.2 1.0 1.0 1.0Water 3.6 3.6 3.6Catalyst - Example I 0.5 -- --Palmityl dimethylamine 0.1 0.1 0.1THANCAT® DM-70.sup.3 -- 1.0 --N-ethylmorpholine -- -- 2.0Toluene diisocyanate(80/20 isomer distribution) 44.5 44.5 44.5Cream time (seconds) 12 9 10Rise time (seconds) 81 68 78Appearance after curing at175° C. for 45 minutes White Pink White Good cells Good cells Good cells______________________________________ .sup.1 A polyester made from adipic acid, trimethylolpropane and diethylene glycol of approximately 2000 molecular weight available from Witco Chemical Co. .sup.2 A silicone product of Union Carbide Corp. .sup.3 A product of Jefferson Chemical Company, Inc., a mixture of 1,4dimethyl piperazine and B,Bdimorpholinodiethyl ether. EXAMPLE III The following demonstrates the use of the catalyst of Example I in a polyether-based flexible urethane foam. ______________________________________THANOL® F-3520.sup.1 200NIAX L-6202.sup.2 2.0Water 8.050% Stannous octoate in dioctylphthalate 0.8Catalyst Example I 0.6Toluene diisocyanate (80/20 isomer distribution) 103.38Cream time (seconds) 8Rise time (seconds) 70______________________________________ .sup.1 A product of Jefferson Chemical Co., Inc., a propoxylated and ethoxylated glycerin of approximately 3500 molecular weight. .sup.2 A hydrolyzable silicone surfactant sold by Union Carbide Corp. EXAMPLE IV The following demonstrates the use of the catalyst here in a rigid polyurethane foam. ______________________________________THANOL® RS-700.sup.1 36.3Silicone DC-193.sup.2 0.5Trichlorofluoromethane 14Catalyst Example I 0.2Dibutyltin dilaurate 0.08Mondur MR.sup.3 48.7Cream time (seconds) 19Tack free time (seconds) 45Rise time (seconds) 60______________________________________ .sup.1 Propoxylated sorbitol with a molecular weight about 700 from Jefferson Chemical Co., Inc. .sup.2 A silicone surfactant sold by DowCorning. .sup.3 A polymeric isocyanate available from Mobay Chemical Co. It has a functionality of about 2.7. EXAMPLE V This example will illustrate the utility of N,N-dimethyl-3-methoxyethoxypropylamine in the preparation of low density (0.5-0.6 pcf) urethane foams. These type foams are particularly useful for packaging applications. This experiment will further show the excellent latent gel characteristics of foams prepared using this catalyst. Latent gel is a measure of the ability of the foam to support a load at a predetermined time before the rise is completed. This property is very important in an assembly line operation where delicate parts or instruments would be encapsulated in foam prior to shipment. The low odor of the subject catalyst would also be especially advantageous in this type of foam. Formulation, details of preparation, and foam properties are shown in the following table: TABLE II______________________________________Formulation Parts______________________________________Thanol SF-2450.sup.a 100Water 20Fluorocarbon R 113.sup.b 45Y-6690 silicone.sup.c 2.0N,N-diethyl-3-methoxyethoxypropylamine 4.0Mondur MR.sup.d 137.8Details of PreparationB-component temperature, °C. 50-55A-component temperature, °C. 50-55Cream time, seconds 3-4Rise time, seconds 35Gel time, seconds 35PropertiesBall penetration, in (25 sec)* 4.0Foam density, pcf 0.55______________________________________ .sup.a Polyol from Jefferson Chemical having a hydroxyl number of 195 and which has a total amine content of 1.14 meq/g. .sup.b Trichlorotrifluoroethane; E. I. DuPont DeNemours and Co. .sup.c Silicone oil from Union Carbide Chemical Corp. .sup.d 2.7 functionality polymeric isocyante; Mobay Chemical Corp. *Procedure for Determination of Latent Gel of Urethane Catalysts As Follows The B-component, comprising a 59.9:12.0:26.9:1.2 weight blend of Thanol SF-2450, water, fluorocarbon R-113, and Y-6690 silicone and a container of Mondur MR polymeric isocyanate were allowed to equilibrate in a 50°-55° C. oven. The B-component (167 g) and test catalyst (3-5 g) were then weighed into a one-quart ice cream container and mixed several seconds using a Hylift stirrer operated at 4200 rpm. Mondur MR (137.8 g) was then quickly poured into the B-component and stirred 1-2 seconds and poured into a 12-in×12-in×6-in cake box. After the foam had risen for 25 seconds, an 8-lb. iron ball was placed on the foam surface and allowed to settle in place. The 8-lb. ball exerts a force of 0.4 psi. To facilitate removal from the foam the ball can be encapsulated in polyethylene film. The amount of identation of the ball into the foam surface is measured with a ruler. The ball penetration figure above demonstrates an excellent latent gel property. EXAMPLES VI AND VII The procedure of Example I was used to prepare N,N-dimethyl-3-methoxypropylamine from 3-methoxypropylamine and N,N,dimethyl-3-ethoxyethoxyethoxypropylamine from 3-ethoxyethoxyethoxypropylamine respectively. EXAMPLE VIII The catalysts of Examples VI and VII were then used to prepare polyester-based urethane foams as per Example II. Results are as follows: TABLE III______________________________________Fomrez® 50 100 100Silicone L-532 1.0 1.0Water 3.6 3.6Palmityl dimethyl amine 0.1 0.1N,N-dimethyl-3-methoxy-propylamine 0.5 --N,N-dimethyl-3-ethoxyethoxy-ethoxypropylamine -- 1.0Toluene diisocyanate 43.8 43.8Cream time (seconds) 8 8Rise time (seconds) 73 67After 45 min. at 175° C. White White______________________________________ EXAMPLE IX The catalysts of Examples VI and VII were also used to prepare low density packaging foam as per Example V. Results are given below. TABLE IV______________________________________THANOL® SF-2450 100 100Water 20 20Trichlorofluoromethane 35 35Silicone Y-6690 2.0 2.0N,N-dimethyl-3-methoxy-propylamine 5.0 --N,N-dimethyl-3-ethoxyethoxy-ethoxypropylamine -- 5.0Mondur MR 137.8 137.8B-component temperature Ambient AmbientA-component temperature Ambient AmbientCream time (seconds) 11 13Rise time (seconds) 50 55Gel time (seconds) 50 60______________________________________
Covers a method of producing a polyurethane by utilizing specific amine compounds as a catalyst in reacting an organic polyisocyanate with an organic polyester polyol or polyether polyol in the presence of said catalyst. Said amines fall within the following structural formula: ##STR1## where R 1 and R are lower alkyl and x=0-2.
2
RELATED APPLICATIONS This subject matter of the present application is related to the following co-pending patent applications, which each have different inventive entities than, but are commonly owned with, the present application: Ser. No. 08/803,180, filed Feb. 19, 1997; Ser. No. 08/943,891, filed Oct. 3, 1997; Ser. No. 08/877,095, filed Jun. 17, 1997; and Ser. No. 09/042,605, filed Mar. 16, 1998. BACKGROUND The present invention concerns the fabrication of integrated circuits and pertains particularly to the removal of photoresist. In fabricating integrated circuits, after the use of photoresist from a photolithography or etch step, the photoresist (or resist) must be removed for the subsequent steps. Resist must be removed following a wide variety of processing steps, including dry etching, wet etching, ion implantation, lift-off processes, high temperature postbake and the removal of misaligned resist patterns for reimaging after development and inspection ("rework"). In addition, wafer surface patterns of several different materials may be present under the resist. Typical materials include silicon dioxide (SiO 2 ), aluminum, polysilicon, silicides and polyimide. It is important when stripping resist to ensure that all the photoresist is removed as quickly as possible without attacking any underlying surface materials. In the prior art, complete removal of polymers generated during etch of high aspect ratio via holes has proved difficult. The etching processes required to control via sidewall profiles and maintain high selectivity to mask and substrate leave polymers that are very difficult to remove. Residual polymers that are not removed will result in vias having higher resistances. These polymers are typically composed of both organic and inorganic components and may require both dry and wet stripping to achieve complete removal. The more difficult the polymer is to remove, the more aggressive the solvent stripper must be, with consequences in safety, cost, and manageability. The burden of strippability can be lessened by making the postetch ash more effective in creating a soluble polymer, and by increasing the dry etch selectivity to the substrate material. Residual polymers also need to be removed in other applications after photoresist etch. It has been shown that the OH radicals produced by a plasma reduce the activation energy for resist removal. See Fujimura, S. et al., "Resist Stripping in an O 2 +H 2 O Plasma Downstream," J. Vac. Sci. Technol. B, 9(2), PP. 357-361 (1991). See also U.S. Pat. No. 5,814,155 issued on Sep. 29, 1998 to Mark A. Levan and Ramiro Solis for PLASMA ASHING ENHANCEMENT. SUMMARY OF THE INVENTION In accordance with the preferred embodiment of the present invention, a CF 4 /H 2 O 2 plasma is used to remove residues remaining after an ashing step. On a substrate, a layer of photoresist is formed over an underlying layer. The layer of photoresist is developed to form a photoresist pattern. The underlying layer is etched using the photoresist as a pattern. The substrate, including exposed areas of the underlying layer, are subjected to a plasma comprising H 2 O 2 vapor and a gaseous fluorocarbon to remove residual polymers. For example, in the preferred embodiment the gaseous fluorocarbon is CF 4 . The CF 4 is introduced into an ashing environment. H 2 O 2 vapor is also introduced into the ashing environment. In one embodiment of the present invention, the residues are removed as part of a process for forming an isolation structure on an integrated circuit using shallow trench isolation. A nitride mask is formed to define a trench area on a substrate of the integrated circuit. The substrate including the trench area are subjected to a plasma comprising H 2 O 2 vapor, and one of a gaseous fluorocarbon or a fluorinated hydrocarbon gas to clean impurities on the trench area. The substrate is etched to form a trench within the trench area. In another embodiment of the present invention, the residues are removed as part of a process for forming a via contact hole in a semiconductor device. A metal layer is formed on a wafer. A dielectric layer is formed on the metal layer. A photoresist layer is formed on the dielectric layer. The photoresist layer is patterned. A via contact hole is formed by an etching process that uses the photoresist as a pattern. The substrate is subjected to a plasma comprising H 2 O 2 vapor and a gaseous fluorocarbon to remove residual polymers. The present invention provides for efficient removal of all residues remaining after an ashing step. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1, FIG. 2 and FIG. 3 illustrate a process to form a via in which sidewall residues are removed in accordance with a preferred embodiment of the present invention. FIG. 4 is a flowchart for a shallow trench isolation process in accordance with a preferred embodiment of the present invention. FIG. 5 and FIG. 6 illustrate the shallow trench isolation process described in FIG. 4 in accordance with a preferred embodiment of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT A CF 4 /H 2 O 2 plasma is used to remove all residues remaining after an ashing step. The presence of CF 4 helps to remove all residues remaining from the ashing step. However, CF 4 also attacks other films. The presence of H 2 O 2 prevents this attack, but still allows efficient removal of residues. In the preferred embodiment of the present invention, when removing residues after forming a photoresist pattern, H 2 O 2 is used as an additive to a CF 4 /H 2 O plasma or as a replacement for H 2 O. Since the structure of H 2 O 2 is composed of two joined OH radicals, it is potentially a greater source of OH radicals than H 2 O which can only produce one OH radical. A plasma that has OH radicals will ash faster (or at a lower temperature) than one consisting entirely of O radicals. Water vapor produces OH in a plasma, but it is not as efficient a source of OH as is H 2 O 2 . H 2 O 2 can be photolytically dissociated, especially by ultraviolet light, which is in abundance in a plasma reaction, i.e., a single molecule of H 2 O 2 when exposed to ultraviolet light produces two molecules of OH. For further information on H 2 O 2 , see Sakugawa, H. et al. "Atmospheric Hydrogen Peroxide," Environ. Sci Technol., 24(10), pp. 1452, 1462 (1990). H 2 O 2 can be used in the same hardware that H 2 O is used in, with an adjustment to the temperature controls for H 2 O 2 's higher boiling point of 150° C., as compared with 100° C. for H 2 O. For example, photoresist is patterned as part of a process to form a via contact hole. This is illustrated by FIGS. 1, 2 and 3. FIG. 1 shows a semiconductor device substrate 100 on which a dielectric layer 101 has been deposited. A metal line composed of a first metal layer 102, second metal layer 103, and third metal layer 104 is formed on the dielectric layer. FIG. 2 shows the semiconductor device following etching of metal layers 102, 103 and 104, deposition of a dielectric layer 105 over the semiconductor substrate, planarization, coating the device with photoresist 106, formation of a mask pattern and etching a via contact hole 110. In etching processes used for forming the via contact hole, the polymer layer 111 on the sidewall of the photoresist layer and on the sidewall of the via contact hole is formed by the reaction of the photoresist layer, dielectric layer, and metal layers. FIG. 3 shows the semiconductor device after selective removal of the sidewall polymer 111 so that third metal layer 104 is not etched. Resist and sidewall polymer 111 are removed using a CF 4 and H 2 O 2 plasma as the etch gas. To achieve the highest selectivity with respect to the third metal layer 104 it is preferable for the ratio of H 2 O 2 to CF 4 flow rates into the reactive chamber to be about 1.67 to 1. In one embodiment, H 2 O 2 and CF 4 are introduced into an ashing environment to form an inductively coupled plasma. For example, H 2 O 2 is introduced at a temperature of 70° C. and at a flow rate of approximately 600 standard cubic centimeters per minute (SCCM). CF 4 is introduced at a flow rate of approximately 360 SCCM. Alternatively, in another embodiment of the present invention, oxygenated gases such as O 2 , H 2 O, gaseous polyfluorocarbons such as C 2 F 6 , or fluorinated hydrocarbons such as CHF 3 , instead of or in addition to CF 4 , are introduced into the ashing environment at a flow rate of approximately 300 SCCM. Alternatively, other flow rates may be used to introduce the gases into the ashing environment. Also, other plasma sources such as microwave, can be used in place of the inductively coupled plasma. Depending on the application, other methods can be used to generate an H 2 O 2 and CF 4 plasma for use in removing photoresist. For example, an ion beam method may be used where the H 2 O 2 and CF 4 plasma is generated in a separate chamber and ions are accelerated towards the substrate surface by means of grids. Alternatively, a method may be used where the H 2 O 2 and CF 4 plasma is generated in a separate chamber away from the substrate to be etched. In this case mainly neutral active species and only very few ions are directed onto the substrate surface by means of the combination of differential pressure and/or magnetic fields. In alternative embodiments, the H 2 O 2 and CF 4 plasma can be used in removing polymer remnants after photoresist etch in other processing applications. For example, FIG. 4 is a flowchart for a shallow trench isolation process in accordance with a preferred embodiment of the present invention. In step 21, a layer of buffer (pad) oxide is formed on a substrate of a semiconductor wafer. For example, the layer of buffer oxide is formed by thermal oxidation of silicon to grow the oxide. The layer of buffer oxide is, for example, 200 Angstroms (Å) thick. In a step 22, a layer of nitride is formed on top of the layer of buffer oxide. For example, the layer of nitride is formed by low pressure chemical vapor deposition (LPCVD, SiH 2 Cl 2 +NH 3 . Dichlorosilane/Ammonia). The layer of nitride is, for example, 2000 Å thick. In a step 23, a layer or resist is deposited and then patterned. The nitride and buffer oxide is then patterned to define a trench area. The resist is then removed. At this point, a special cleaning optionally can be performed. For example, the semiconductor wafer is placed in an ashing environment such as, for example, an inductively coupled plasma. Although such an ashing environment is used in the present embodiment, the present invention is also well suited to the use of various other well known ashing environments. In one embodiment, the ashing environment operates at a pressure of approximately 1.2 Torr and a power of approximately 900 Watts. H 2 O 2 and CF 4 are then introduced into the ashing environment to form an inductively coupled plasma. For example, H 2 O 2 is introduced at a flow rate of approximately 600 standard cubic centimeters per minute (SCCM). CF 4 is introduced at a flow rate of approximately 360 SCCM. Alternatively, in another embodiment of the present invention, oxygenated gases such as O 2 or H 2 O, gaseous polyfluorocarbons such as C 2 F 6 , or fluorinated hydrocarbons such as CHF 3 , instead of CF 4 , are introduced into the ashing environment at a flow rate of approximately 300 SCCM. Alternatively, other flow rates may be used to introduce the gases into the ashing environment. Also, other plasma sources such as microwave, can be used in place of the inductively coupled plasma. For example, in one embodiment of the present invention, the ashing environment comprising H 2 O 2 vapor and the gaseous fluorocarbon or a fluorinated hydrocarbon gas, efficiently and thoroughly removes water spots or polymer contaminants introduced over the trench area. In a step 24, a conventional clean of the trench area is performed. The clean is performed, for example, with wet chemicals such as sulfuric acid and hydrogen peroxide. The clean typically ends with a spin-rinse-dry (SRD). FIG. 5 illustrates the result of the completion of step 24. In FIG. 5, on top of a silicon substrate 30, sections 32 of a nitride layer are over sections of a buffer oxide layer 31. The trench area is clean. In a step 26, a trench is formed by, for example performing a dry etch of the silicon wafer. The dry etch can be one or more steps to etch the silicon and smooth out the sidewall profile. FIG. 6 illustrates the result of the completion of step 26. In FIG. 6, a trench 33 is shown etched in silicon substrate 30. For example, trench 33 is 0.5 microns wide and extends 0.4 microns below the surface of substrate 30. The substrate is etched to form a trench within the trench area. At this point, a special cleaning can again be performed. For example, the semiconductor wafer is placed in an ashing environment such as, for example, an inductively coupled plasma. Although such an ashing environment is used in the present embodiment, the present invention is also well suited to the use of various other well known ashing environments. In one embodiment, the ashing environment operates at a pressure of approximately 1.2 Torr and a power of approximately 900 Watts. H 2 O 2 and CF 4 are then introduced into the ashing environment to form an inductively coupled plasma. For example, H 2 O 2 is introduced at a flow rate of approximately 600 standard cubic centimeters per minute (SCCM). CF 4 is introduced at a flow rate of approximately 360 SC CM. Alternatively, in another embodiment of the present invention, oxygenated gases such as O 2 or H 2 O, gaseous polyfluorocarbons such as C 2 F 6 , or fluorinated hydrocarbons such as CHF 3 , instead of CF 4 , are introduced into the ashing environment at a flow rate of approximately 300 SCCM. Alternatively, other flow rates may be used to introduce the gases into the ashing environment. Also, other plasma sources such as microwave, can be used in place of the inductively coupled plasma. For example, in one embodiment of the present invention, the ashing environment comprising H 2 O 2 vapor and the gaseous fluorocarbon or a fluorinated hydrocarbon gas, efficiently and thoroughly removes water spots or polymer contaminants within the trench. The foregoing discussion discloses and describes merely exemplary methods and embodiments of the present invention. As will be understood by those familiar with the art, the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosure of the present invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.
A CF 4 /H 2 O 2 plasma is used to remove residues remaining after an ashing step. On a substrate, a layer of photoresist is formed over an underlying layer. The layer of photoresist is developed to form a photoresist pattern. The underlying layer is etched using the photoresist pattern. The substrate, including exposed areas of the underlying layer, are subjected to a plasma comprising H 2 O 2 vapor and a gaseous fluorocarbon to remove residual polymers.
7
FIELD OF THE INVENTION This invention relates to the field of direct nucleic acid detection, particularly RNA in low copy number, without a requirement for amplification of either the number of RNA molecules, or by amplification of a detection signal. The method further utilizes capillary electrophoresis to detect a target RNA-DNA probe hybrid band. The invention also combines laser-induced fluorescence and capillary electrophoresis. BACKGROUND OF THE INVENTION The quantitation of RNA, particularly RNA derived from infectious agents or from cellular sources, is important in the diagnosis and monitoring of disease states caused by such agents. For example, the viral load detected in serum correlates to high concentrations of virus in the lymph nodes and has predictive value in assessing progression of AIDS to advanced stages, as reported in Ho, et al., Nature, 373: 123 (1995) and Mellors, et al., Ann. Intern. Med., 122: 573 (1996). Viral titers in serum are also correlated with disease progression for other viruses such as HCV, nonA nonB hepatitis other than HCV, and atypical lentiviruses. There are several fundamental problems in RNA quantitation in low copy number. If there are too few molecules to detect by conventional means, amplification of the target sequence to increase its numbers by several logs is necessary. However, the coefficients of variability (CV) may often exceed 20 percent or more, so that the result obtained is unreliable, and does not correlate with the stage of disease. The coefficient of variability (CV) is defined as the standard deviation of the values obtained divided by the mean. Increased signal from a small number of target molecules is another approach, but the final result depends upon a large number of reactions which must occur in correct sequence. Again, there is a large CV because of reaction sequence errors giving a spectrum of values. Alternatively, direct measurement of the low RNA copy number in the native sample, even where adequate detection sensitivities can be achieved, is thwarted by the inherent instability of RNA-DNA duplexes. Increasing the length of the hybridized target can increase both sensitivity and stability of the hybrid, but the additional nucleotide sequence combinations increase the chance of nonspecific hybridizing to fragments of host nucleic acids or partial hybridization to nonselected regions of the viral genome, thereby contributing to a falsely inflated positive value. Most of the improvements to date in low RNA copy number quantitation represent attempts to better control the multiple molecular events involved in signal or nucleic acid amplification strategies. The three main amplification systems currently available include branched chain signal amplification (bDNA), reverse transcriptase polymerase chain reaction (RT-PCR), and nucleic acid sequence based amplification (NASBA). The strategy of the first two, bDNA and RT-PCR, involves using a first reaction step that converts the system from an RNA target to a DNA target. In bDNA an initial probe hybridizing with a complementary probe contains a plurality of noncomplementary sites capable of hybridizing to further DNA strands, which in turn may hybridize sites noncomplementary to the probe sequence, so that as repeated layers of hybridization occur, a branched DNA structure of extreme complexity is created. The last to be annealed strand in the branched structure carries a reporter. Thus the original RNA target molecule gives rise to an amplification of the signal generating capability of the system. A full explanation and description of the bDNA technique is set forth in Fultz, et al., "Quantitation of plasma HIV-I RNA using an ultra sensitive branched DNA (bDNA) assay", in Program and Abstracts of the 2nd National Conference on Human Retroviruses (1995), and product literature, L-6170 Rev. 5.0 for the Quantiplex™ HIV-RNA Assay (Chiron Corporation). In RT-PCR a cDNA is generated from the RNA template, and then an ordinary PCR amplification ensues utilizing selected primers to define the left and right ends of the amplicon. Each successive round of synthesis and denaturation causes an exponential increase in the number of progeny strands generated in the system. After the amplification is complete, a probe having a complementary sequence to some portion of the amplicon and carrying a reporter can be used for detecting the amplified target. In both RT-PCR and bDNA, the original RNA target can theoretically be dispensed with, without impairing the sensitivity of the test, once the conversion to a DNA system has occurred. These methods effectively get around the inherent lability of the RNA target or its RNA-DNA duplex hybrid. Similarly, both RT-PCR and bDNA share many of the same deficiencies. Both systems rely upon the integrity of a large number of successive hybridization events. If an early hybridization event fails, for any of a number of reasons such as structural (steric) hindrance, uncorrected mismatch, binding of a defective enzyme molecule, etc., the final number of copies, and therefore the intensity of the signal will be ablated. These random occurrences help to account for the great sensitivity of the assays coupled with a widely variable coefficient of variability. The commercial form of the test normalizes variability by co-amplification of an internal standard. To control for variability the internal standard must be amplified under identical conditions as the target yet be able to be differentiated from the target, an almost impossible task. Also, introducing an internal standard changes the PCR reaction kinetics itself. RT-PCR, while showing some efficacy, is in practice very labor intensive, and not practical under normal clinical laboratory conditions. In NASBA, the lability of RNA is overcome by increasing copy number to a vast number. The technique involves creating a cDNA from the target RNA and then generating a large number of transcripts from bDNA template, which in turn can be converted to a cDNA, and so on. The number of transcripts produced is always much greater than the number converted to cDNA, so that a large excess of RNA occurs. The process is initiated upon annealing of two primers, one of which contains a phage promoter, which in the ensuing cDNA provides a point of initiation for transcription. Unlike PCR where the numbers of actual cycles of amplification are nominally controlled by the number of temperature cycles, there is much less control in NASBA. The technique suffers from a lack of uniformity as between different target sequences, and in the same target sequence from one run to another. The commercial form of the assay employs three internal calibrators, which are co-amplified with the target sequence. In any detection technique it is desirable for the analytical coefficient of variability (CV) to be less than 15 percent. The three techniques were recently compared in a study by Coste, et al., J. Med. Virol., 50: 293 (1996). bDNA was found to be most reproducible with CVs ranging from 6-35 percent. Better results were achieved at high copy number, 12.4% vs. 31% for low copy number. However, sensitivity was only 68 percent with a lower level of detection at 4000 HIV equivalents. NASBA was the least reliable test with CVs ranging from 13-62 percent, with CV averages of 20.7 percent for high copy number and 41.8 percent for low copy number. Sensitivity was 100 percent with a lower level of detection at 2600 HIV equivalents. Finally, RT-PCR has a sensitivity of 93 percent, but a mean CV of 43 percent. While improvements in the foregoing techniques may result from optimization of the operating conditions of the assays, and from discovery of reagent combinations that minimize interferences with hybridizations, it is unlikely that variability will ever be reduced uniformly to coefficient values less than 15 percent. This is because priming errors and hybridization interferences cannot be entirely overcome, and misevents occurring early in the sequence of amplification steps have a geometric impact on the result. Thus the wide range of CV. If the level of sensitivity for direct detection of RNA could be increased by several orders of magnitude over standard UV detection methods, and the problem of RNA-DNA duplex instability be solved, direct detection would provide a viable alternative to current amplification-based methods without loss of reliability. SUMMARY OF THE INVENTION In the method of the present invention, two different dye molecules are utilized to produce a characteristic signal emission upon excitation with a laser beam. RNA is extracted from a cell-free biological specimen such as serum or from a cellular RNA source, hybridized to a fluorescent DNA probe (first dye molecule covalently attached to probe) of complementary sequence to form an RNA-DNA hybrid, applied as the hybrid RNA-DNA duplex to a capillary electrophoresis column, electrophoresing in a hybrid band in the presence of an intercalating dye (second dye in electrophoresis buffer), and quantitatively detecting the amount of RNA-DNA hybrid by measuring the total fluorescent intensity of light emitted from the hybrid band upon excitation by laser-induced fluorescence, and decay of the excited molecules to light of a longer wave length. In capillary electrophoresis, the sample containing the RNA-DNA hybrid is loaded onto the gel column and an electric current is applied to the gel matrix. The dye which permeates the gel matrix, is capable of intercalating the hybrid, and binds to the interstices of the duplex, so that these intercalated molecules migrate with the hybrid band. The unbound dye molecules are not seen as background because its quantum yield varies in the presence of nucleic acid. The band is quantitated by directing a scanning laser-induction beam along the gel. The hybrids with pendant dye (both covalently attached and bound by electrostatic interaction), migrating as a band, absorb the light of excitation wavelength, and emit at a lower energy wavelength. Peak areas of light emission intensity are identified. The total fluorescence is the sum of the fluorescence values under the peak. Applicants have discovered that the configuration of terminal labelling of the DNA probe with one dye type, and allowing intercalating of the duplex hybrid by a second dye type has the unexpected benefit of dramatically increasing the stability of the hybrid. Hence, the present invention provides a method for stabilizing during capillary electrophoresis nucleic acid hybrids consisting of an RNA strand and a fluorophore terminally labelled DNA strand of short length (15 to about 40 base pairs in length) which involves only electrophoresing the nucleic acid hybrid in the presence of an intercalating dye. Any dye, preferably which fluoresces at the same wavelength as the dye covalently attached to the DNA probe, capable of intercalating double stranded nucleic acids will be efficacious in increasing stability. The ability to stabilize short RNA-DNA duplexes means that an RNA target sequence can now readily be selected having less than 5 percent homology to any other portion of the target, and non-homology to host nucleic acids, as verified by a GenBank search or by comparison to other published sequence databases. The present invention also provides a kit containing the key ingredients for carrying out a direct quantitative test for HIV-1 and other targets suspected of being present in a biological specimen utilizing capillary electrophoresis and laser-induced fluorescence. The kit contains a quantity of a DNA probe of 15 to 30 nucleotides labelled with a fluorophore at its 3',5' terminus, or at both termini, whose sequence is complementary to an RNA sequence having less than 5% homology to any other sequence of commensurate length contained within the target gene, or other host genome. The kit also provides a quantity of a fluorescent dye capable of intercalating an RNA-DNA hybrid molecule of 15-30 base pairs. The vessels containing the reagent probe and dye are made of materials to which the reagents do not adhere, such as surface-treated borosilicate glass, polypropylene and the like, and are shaped to accommodate an automatic pipetter tip. The methods and reagents of the present invention fulfill the following advantages and objectives: fast and highly reliable direct assay for quantitative determination of RNA a low coefficient of variability even at low copy number of RNA lower cost than amplification-based tests greater sensitivity than any other direct gene quantitation method. BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1A-1C are electropherograms of cellular RNA (1.856 μg/μL) obtained from Spodoptera frugiperda culture. FIG. 1A represents an injection at time 0. A second injection of same sample after 30 minutes at room temperature is shown in FIG. 1B. FIG. 1C shows a third injection of same sample after 60 minutes at room temperature. FIG. 2 is an electropherogram analysis of fluorescently labeled HIV specific probe alone diluted in DEPC treated water to a concentration of 72 fg/7.1 nL, which elutes at 11 min. FIGS. 3A-3C show an electropherogram analysis of hybridization products. RNA samples obtained from a HIV seropositive patient and a seronegative volunteer were hybridized with a HIV specific probe and analyzed as described in experimental. FIG. 3A represents a HIV RNA/Probe complex elutes at 12 min, indicating the presence of HIV RNA in the patient's serum. FIG. 3B represents a seronegative volunteer. FIG. 3C is a negative control containing all reaction components except RNA. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT A basic problem in direct gene quantitation which Applicants have overcome is the extreme lability of target RNA-DNA duplexes under conditions of electrophoresis. Interestingly, the use of carrier RNA to stabilize the target RNA and the double stranded nucleic acid of the hybrid, is unavailing. Experiments utilizing carrier RNA, as set forth in Example 3, Table 4, show that there is no stabilization of the RNA-DNA hybrid having the sequence of Seq. I.D. No. 1 in the presence of carrier. Normally, carrier nucleic acid or protein, in the case of proteinaceous targets, function as a coprecipitant, or compete for a degradative enzyme, thereby protecting the target species through shear overwhelming numbers. Failure of carrier RNA to mitigate degradation of the hybrid is consistent with the conclusion that the RNA-DNA hybrid of short length is inherently unstable, and its lability is not due to a contaminating nuclease, or other process for which a carrier population can exert protection or rescue. Since the lability appears to be activated by the electric current, separation of tRNA from duplex may cause a loss of whatever protection might otherwise be afforded. Isolating RNA from biological specimens may be carried out by any conventional method which takes precautions in minimizing RNA degradation. Accordingly, procedures involving heat or strong acid/base reagents are to be avoided. In preparing specimens from serum, blood is centrifuged to remove cells, and then extracted. There are several extraction kits commercially available for this purpose, as, for example, the Ultraspec II RNA isolation system from Biotex. The probe sequence is selected for uniqueness within the genome of the organism to be detected and monitored, and which is unlikely to show any homology for the host genome. This is important because it is impossible to guarantee that all cells contained in the specimen will be removed by centrifugation. The degree of homology between the probe sequence and the remainder of the target genome should be as low as possible, but less than 5 percent. Thus, it is important to select a sequence long enough to confer selectivity and short enough to avoid partial homologies with non-target RNAs. The DNA probe will have a nucleotide sequence of about 15 to 50 bases, preferably between 20 and 30 bases. In the case of HIV-1, a unique, genetically stable 26 base sequence from the pol gene was selected, having the sequence 5'-ACAGTATTAGAAGAYATGRRTTTGCC-3' (Seq. I.D. No. 1) (in which Y=A or C; and R=A or G). This sequence is identified in GenBank as entry U62632. A probe terminally labelled with a fluorophore at the 5' end and having the sequence given above which is complementary to the HIV-1 sense strand was prepared synthetically utilizing 5'-fluorescein phosphoramidite. Another sequence of interest in HIV quantitation is: 5'-GGCAAARRCATYTCTTCTAATACTGT-3' (Seq. I.D. No. 2). Also, the following sequences are useful in the present invention for quantitation of Quinone Acceptor Oxidoreductase and Human Topoisomerase I, respectively. NAD(P)H: 5'-TCGGACCTCTATGCCATGAACT-3' Seq. I.D. No. 3 5'-AGTTCATGGCATAGAGGTCCGA-3' Seq. I.D. No. 4 5'-AGGCTGGTTTGAGCGAGTGTTC-3' Seq. I.D. No. 5 5'-GAACACTCGCTCAAACCAGCCT-3' Seq. I.D. No. 6 5'-CAGCAGACGCCCGAATTCAAAT-3' Seq. I.D. No. 7 5'-ATTTGAATTCGGGCGTCTGCTG-3' Seq. I.D. No. 8 Human Topoisomerase I: 5'-AGAGACCTCGAGATGAGGATGA-3' Seq. I.D. No. 9 5'-TCATCCTCATCTCGAGGTCTCT-3' Seq. I.D. No. 10 5'-TCTCGTATTTCTGCCAGTCCTT-3' Seq. I.D. No. 11 5'-AAGGACTGGCAGAAATACGAGA-3' Seq. I.D. No. 12 Applicants sought to utilize an intercalating fluorescent dye to visualize a band of probed RNA migrating on an electrophoresis column. It was found, however, that for short (15-30) base pairs neither a fluorescein labelled DNA probed RNA duplex without intercalating dye, or a non-terminally labeled DNA probed RNA duplex in the presence of an intercalating dye alone was stable during electrophoresis. However, the combination of a terminally fluorophore labeled DNA probe and the presence of an intercalating fluorescent dye produced remarkable stability of the duplex, for reasons not yet understood. The preferred terminal fluorophore is fluorescein, although others such as rhodamine, or the BODIPY series (Molecular Probes, Inc.) may be utilized also. The preferred intercalating dye is thiazole orange, although other dyes such as YOYO (also available from Molecular Probes, Inc., and whose structure is given at p.155 of its 1996 Catalogue for Product No. Y-3601) may be used. When using a laser-induced detection system, it is preferable from a sensitivity standpoint, to use terminating and intercalating dye pairs which emit light at the same wavelength, thereby boosting the signal additively, see Table 3. Fluorescein and thiazole orange absorb at 488 nm and emit at 520 nm. For probe manufacture, fluorescein is ideal because of its ease of use, well known coupling chemistries, and its low cost. Thiazole orange is more expensive, but in the capillary mode of electrophoresis, the small volumes reduce usage. In an alternate embodiment of the present method, the intercalating dye may be taken up by the DNA-RNA hybrid prior to loading on the gel. Utilizing the combined dyes prevents degradation of the RNA-DNA hybrid, and also increases sensitivity to levels comparable to other methods. The most sensitive assay system will be the best system for monitoring HIV, and with a lower detection limit of 50 μg this system is more sensitive than other available methods. The lower limit of the linear range is 11 picograms to 72 femtograms, which provides a lower detection limit of 7200 HIV equivalents per ml compared to 10,000 equivalents for bDNA. The greater sensitivity of RT-PCR (350 equivalents/ml) has a precision of only 11-93 percent, whereas in the present method of direct detection, the CV is always less than 15 percent for peak area (total fluorescence). The precision (CV) of peak position in the gel (lapsed time) is less than 1 percent. In hybridization assays of actual patient specimens producing RNA-DNA hybrids, reliable and quantitative detection of less than 2000 equivalents of HIV could be achieved. The technique of capillary electrophoresis (CE) is utilized in the present method. A discussion of methods applicable to the Beckman instrument used in the experiments set forth in the Examples is given in Altria, et al., Quantitative Applications of Capillary Electrophoresis in Pharmaceutical Analysis, Beckman:1994, Publication No. 538703, and Altria, Capillary Electrophoresis Guidebook, Humana Press: 1995. CE has been applied to direct quantitation of HIV-1 in patients having high serum levels of HIV-1. Ferandez-Arcas, et al., J. Acq. Immune Defic. and Hum. Retrobiol., 12: 107 (1996) reported detection by direct UV analysis of extracted RNA at levels of greater than 10 8 virions/ml correlated to the very high levels of circulating virus in early infection. This direct technique, even with the enhancement expected with laser-induced fluorescence is not sensitive enough to monitor anti-HIV drug therapy where levels of circulating virus decline. For further comprehensive materials on conventional methods and applications of capillary electrophoresis, please see Landers, Handbook of Capillary Electrophoresis, CRC Press: 1997. Other advantages of the present invention will be apparent from the Examples which follow. EXAMPLE 1 Sample Collection and RNA Extraction RNA was obtained from a HIV seropositive patient by centrifugation of whole blood at 3,000×g for 15 min at 4° C. on a Centra GP8R (International Equipment Corporation, Needham Heights, Mass., U.S.A.) refrigerated centrifuge. The plasma was separated and stored at -80° C. RNA was extracted from plasma samples using the Ultraspec II RNA isolation system (Biotex, Houston, Tex., U.S.A.) as recommended by the manufacturer. RNA was extracted from both plasma and peripheral blood lymphocytes of a HIV seronegative normal volunteer. RNA was also obtained from Spodoptera frugiperda 21, grown in TC-100 serum (HyClone, Logan, Utah, U.S.A.) at 27° C. RNA was resuspended in DPEC treated water (Biotex, Houston, Tex., U.S.A.) and quantitated spectrophotometrically. Probe Synthesis and Hybridization To ensure specificity, a unique gene sequence is probed. The pol region is the most genetically unique of the HIV genome and a 26 bp sequence in this region was selected (GenBank entry U62632). Uniqueness was verified by a GenBank search. A 5'-fluorescein phosphoramidite (Glenn Research, Sterling, Va., U.S.A.) (probe sequence=5'-ACAGTATTAGAAGAYATGRRTTTGCC-3') labeled DNA probe for this sequence was synthesized by the University of Wisconsin Biotechnology Center (Madison, Wis., U.S.A.). Sample RNA present in a concentration of 0.095 μg/μL was diluted serially with DEPC treated water and hybridized with the DNA probe (1.0125 μg) in a buffer volume of 30 μL containing 10 mM Tris-HCl (pH 7.2), 1 mM EDTA (pH 8.0), 50 mM NaCl, and 1 mM cetyltrimethylammonium bromide (CTAB) (ACROS, Pittsburgh, Pa., U.S.A.). The mixture was heated at 85° C. for 10 min, and then incubated at 42° C. for 4 h. The addition of CTAB to the hybridization, as reported by Pontius, et al., Proc. Natl. Acad. Sci., 88:8237 (1991). Following incubation, samples were digested for 30 min at 37° C. with RNAase One (4.5 U) (Promega Corporation, Madison, Wis., U.S.A.) in a digestion buffer of 50 μL consisting of 50 mM Tris-HCl (pH 7.2), 5 mM EDTA (pH 8.0). Samples were flash frozen at -80° C. to stop enzymatic digestion. EXAMPLE 2 CE-LIF Analysis Separations were performed on a P/ACE 2050 CE system (Beckman Instruments, Fullerton, Calif., U.S.A.) with the temperature held constant at 20° C. Detection of hybridization samples was achieved using laser-induced fluorescence in the reversed-polarity mode (anode at the detector side) at excitation of 488 nm and emission of 520 nm. Samples were introduced hydrodynamically by 10 s injections at 0.34 Pa across a 65 cm×100 μm coated eCAP dsDNA capillary filled with replaced linear polyacrylamide (Beckman Instruments, Fullerton, Calif., U.S.A.). The capillary was conditioned with eCAP dsDNA 1000 gel buffer which contained 60 μL of LiFluor dsDNA 1000 EnhanceCE (thiazole orange) intercalator per 20 mL (Beckman Instruments, Fullerton, Calif., U.S.A.). Separation were performed under constant voltage at 7.0 kV for 15-30 min. The capillary was rinsed with gel buffer for 3 min prior to each injection. The capillary was calibrated with the fluorescently labeled probe and a mixture of RNA molecular markers (Ambion, Austin, Tex., U.S.A.). The 5 markers ranged in size from 100-500 bp. Postrun analysis of data was performed using the System Gold chromatography data system (Beckman Instruments, Fullerton, Calif., U.S.A.). Referring to Table 1, the stabilities of various calibrator RNA standards is given. The low CV percentages indicate that CE is highly precise with respect to variation both in terms of total fluorescence (peak area) and migration time on the gel. TABLE 1______________________________________Stability of Cellular RNA at Room Temperature______________________________________Peak Area Peak Injection 5S 16S 18S 23S 28STime 0 1523 2891 586 2717 921 Time 30 min 1277 2605 650 2368 1002 Time 60 min 1371 2603 598 2183 911 Mean 1390.33 2699.67 611.33 2422.67 944.67 St dev 124.13 165.70 34.02 271.1 49.9 CV % 8.9 6.1 5.5 11 5 % change over -17 -10 +10 -13 -8 30 min % change over -10 -10 +2 -20 -1 60 minMigration Time Injection Time 0 11.96 12.17 13.45 14.58 16.68 Time 30 min 11.94 12.21 13.44 14.54 16.64 Time 60 min 11.94 12.20 13.45 14.55 16.66 Mean 11.95 12.19 13.45 14.56 16.66 St dev 0.012 0.021 0.006 0.021 0.02 CV % 0.1 0.1 0.04 0.1 0.1______________________________________ Table 2 compares the detection limits and reproducibility for duplex combination of RNA/RNA, RNA/DNA, and DNA/DNA. The lower detection limit for DNA/DNA is explained by the greater known number of dye molecules intercalating that duplex than for RNA/RNA. All CV values were less then 15 percent. TABLE 2______________________________________Comparison of Detection Limits and Reproducibility of Various Nucleotide Complexes Minimum Detectable Quantity PrecisionNucleotide HIV Migration Peak Complex Weight equivalents Time CV % Area CV %______________________________________RNA/RNA 500 fg 50,000 0.16-1.1 0.9-1.0 DNA/DNA- 36 ag 4 0.18-0.22 7.3-11 Fluorescein DNA/RNA- 190 ag 21 0.18-0.22 5.6-7.3 Fluorescein______________________________________ Table 3 shows that the total fluorescence when both a terminal dye and an intercalating dye are used is additive when emission takes place at the same wavelength. The low panel shows the dramatic contribution to duplex stability of the dye combination. TABLE 3______________________________________1. Synergy Experiment: DNA/DNA hybrids Peak Area (rounded to Dye nearest 10,000 rfu)______________________________________ FL alone 90,000 TO alone 10,000 FL + TO 100,000______________________________________2. Stability Experiment DNA/RNA hybrids Degradation (% Complex decrease in peak area) Retention time CV______________________________________ FL + TO <5% <0.5% FL 41-45% >70% TO 31-33% 1%______________________________________ EXAMPLE 3 Analysis of Low Copy HIV RNA by Addition of Carrier RNA Serum obtained from HIV seropositive patient #31 was serially diluted with sterile double distilled H 2 O. The original sample contained 5×10 5 HIV copies per ml and five dilutions were made, the most dilute containing 10 copies of HIV RNA per ml. E. Coli tRNA (100 mcg) was added to the diluted samples, and the hybridizations to labelled probe were carried out. RNA was then extracted by Ultraspec II RNA Isolation System, hybridized as usual and analyzed by CE-LIF. TABLE 4______________________________________Copies HIV per Weight Peak Area (ND = ml scrum equivalent not detectable)______________________________________5 × 10.sup.5 50 pcg 9768 10.sup.5 10 pcg 2437 10.sup.4 1 pcg ND 10.sup.3 100 fmt ND 10.sup.2 10 fmt ND 10 1 fmt ND______________________________________ The failure to detect viral RNA at higher dilutions indicates that the hybrids are unstable, even in the presence of carrier tRNA. Contrast this to extracting RNA then serially diluting. Detection limits are 1.9 fg for DNA/RNA complexes. __________________________________________________________________________# SEQUENCE LISTING - - - - (1) GENERAL INFORMATION: - - (iii) NUMBER OF SEQUENCES: 12 - - - - (2) INFORMATION FOR SEQ ID NO:1: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 26 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: DNA (genomic) - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:1: - - ACAGTATTAG AAGAMATGRR TTTGCC - # - # 26 - - - - (2) INFORMATION FOR SEQ ID NO:2: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 26 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: DNA (genomic) - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:2: - - GGCAAARRCA TMTCTTCTAA TACTGT - # - # 26 - - - - (2) INFORMATION FOR SEQ ID NO:3: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 22 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: DNA (genomic) - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:3: - - TCGGACCTCT ATGCCATGAA CT - # - # 22 - - - - (2) INFORMATION FOR SEQ ID NO:4: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 22 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: DNA (genomic) - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:4: - - AGTTCATGGC ATAGAGGTCC GA - # - # 22 - - - - (2) INFORMATION FOR SEQ ID NO:5: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 22 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: DNA (genomic) - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:5: - - AGGCTGGTTT GAGCGAGTGT TC - # - # 22 - - - - (2) INFORMATION FOR SEQ ID NO:6: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 22 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: DNA (genomic) - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:6: - - GAACACTCGC TCAAACCAGC CT - # - # 22 - - - - (2) INFORMATION FOR SEQ ID NO:7: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 22 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: DNA (genomic) - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:7: - - CAGCAGACGC CCGAATTCAA AT - # - # 22 - - - - (2) INFORMATION FOR SEQ ID NO:8: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 22 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: DNA (genomic) - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:8: - - ATTTGAATTC GGGCGTCTGC TG - # - # 22 - - - - (2) INFORMATION FOR SEQ ID NO:9: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 22 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: DNA (genomic) - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:9: - - AGAGACCTCG AGATGAGGAT GA - # - # 22 - - - - (2) INFORMATION FOR SEQ ID NO:10: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 22 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: DNA (genomic) - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:10: - - TCATCCTCAT CTCGAGGTCT CT - # - # 22 - - - - (2) INFORMATION FOR SEQ ID NO:11: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 22 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: DNA (genomic) - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:11: - - TCTCGTATTT CTGCCAGTCC TT - # - # 22 - - - - (2) INFORMATION FOR SEQ ID NO:12: - - (i) SEQUENCE CHARACTERISTICS: (A) LENGTH: 22 base - #pairs (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear - - (ii) MOLECULE TYPE: DNA (genomic) - - (xi) SEQUENCE DESCRIPTION: SEQ ID NO:12: - - AAGGACTGGC AGAAATACGA GA - # - # 22__________________________________________________________________________
A direct quantitation of RNA contained in a sample is obtained by capillary electrophoresis of the RNA hybridized to a DNA probe of complementary sequence stabilized by the combination of a fluorophore terminally conjugated to the DNA probe and a dye intercalating the RNA-DNA hybrid so formed. The RNA is quantified by measuring the total fluorescence emitted by the electrophoresed hybrid upon excitation by a laser generated light beam.
2
BACKGROUND OF THE INVENTION [0001] Global positioning system (GPS) devices have become useful for many activities. Global positioning systems work through use of signals received from satellites transmitting global positioning system signals. GPS signals tend not to be available indoors, so GPS devices cannot determine GPS coordinates. SUMMARY OF THE INVENTION [0002] An embodiment of the invention is a method or corresponding apparatus or system of providing indoor localization. The method comprises emitting signals at multiple fixed locations within an indoor facility. This signals are unique at each location relative to the signals at adjacent locations. [0003] Optionally, the signals are unique at every location of the multiple fixed locations within the indoor facility. [0004] The method may include emitting signals that are human-imperceptible signals. Emitting the human-imperceptible signals may include emitting ultrasonic signals. Alternatively, emitting the human-imperceptible signals may include emitting signals at non-visible optical wavelengths. [0005] Emitting the signals may alternatively include emitting signals perceptible by a mobile electronics device. In such a case, emitting the signals may include emitting signals encoded to match a location within a facility known to the mobile electronics device by way of a look-up table. [0006] Emitting the signals may include emitting multiple tones (i.e., frequencies) at or above 20 kHz separated by at least 250 Hz and at or below 40 kHz at each location within the indoor facility. The combination of tones at each location may be different from the combination of tones at each other location. The combination of tones at adjacent locations may be sufficiently distinguishable that cross-talk between signals at adjacent locations does not negatively impact the mobile electronics device from identifying its present location. [0007] Emitting the signals may further include emitting a composite of multiple signals of different frequencies without modulation or emitting a composite of multiple signals of different frequencies with modulation on at least one of the frequencies. In another embodiment, emitting the signals includes emitting a single frequency having a unique modulation at a given location relative to signals at adjacent locations. [0008] The method may further comprise transmitting a mapping of the signals corresponding to the multiple fixed locations to a mobile electronics device for the mobile device's use in determining its location based on signals it senses at a location. [0009] The indoor facility may be a building with multiple floors and multiple rooms, such as offices, on each floor. In the building, the emitting of the signals may include emitting signals encoded according to a three-dimensional grid corresponding to floors and rooms on each floor. [0010] Another embodiment of the present invention includes a system for providing indoor localization. The system may include a controller having access to a mapping of multiple fixed locations within an indoor facility. The mapping may include parameters for signals to be emitted at the multiple fixed locations, where the parameters may be unique for each location relative to parameters at adjacent locations or unique with respect to all other locations. The system further includes a signal generator at each location configured to generate a signal corresponding to a respective parameter. The system still further includes an emitter at each location coupled to the respective signal generator and configured to emit a signal according to the respective parameter, with the signals at the multiple fixed locations within the indoor facility being unique at each location relative to signals at adjacent or all other locations. The system may include additional elements that can be configured to perform operations consistent with the above-described method. [0011] Another embodiment of the present invention includes a mobile electronics device. The mobile electronic device comprises a transducer and a receiver coupled to the transducer, with the receiver being configured to convert a signal sensed by the transducer at a location, among multiple fixed locations in an indoor facility, into a representation of the signal. The representation is unique for the location relative to a representation at an adjacent location. The mobile electronics device further includes a mapping module configured to convert the representation of the signal into a corresponding indication of the location at which the transducer sensed the signal, with the indication being correspondingly unique relative to indications of adjacent locations in the indoor facility. [0012] The mobile device may also include a noise reduction module in the receiver to reduce noise associated with the signal sensed by the transducer. In another embodiment, the receiver may include a Doppler compensation module to reduce effects of Doppler caused by movement of the mobile electronics device, particularly in the indoor facility that includes multi-path effects. BRIEF DESCRIPTION OF THE DRAWINGS [0013] The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention. [0014] FIG. 1 is a diagram of an indoor environment, such as a multi-story building, that may employ an embodiment of the present invention; [0015] FIG. 2 is a diagram of an entrance way to an indoor environment at which a mobile electronics device receives a mapping, such as a table of correspondences, that maps signals, which the mobile electronics device will receive in the indoor environment, to locations within the indoor environment; [0016] FIG. 3 is a table of correspondences illustrating room numbers and tones, such as ultrasonic tones, that can be used to distinguish rooms from each other according to a pattern of the tones; [0017] FIG. 4 is a network diagram of an indoor facility network; [0018] FIG. 5 is a schematic diagram of a mobile electronics device according to an embodiment of the present invention; and [0019] FIG. 6A is a screen capture of signals used within the indoor facility that illustrates a combination of frequencies used to distinguish one location from another location; and [0020] FIG. 6B is a timing diagram that includes two different waveforms that use modulation to distinguish different rooms from each other in the indoor facility. DETAILED DESCRIPTION OF THE INVENTION [0021] A description of example embodiments of the invention follows. [0022] FIG. 1 is a diagram of an indoor facility (also referred to herein as a building) 100 , such as a multi-story building, in which an embodiment of the present invention may be employed. Each room in the building 100 includes an emitter 105 that generates a signal 103 that is unique from other signals in other rooms. The building has multiple floors, floor 1, floor 2, and so forth, and multiple rooms within the floors, such as floor 1, room A1 (“room A1”), floor 1, room A2 (“room A2”), . . . , floor 1, room A3, floor 2, room A1 (“room 2A1”), and so forth. [0023] The emitters 105 transmit the signals 103 into the mobile electronics device 110 rooms, and a person 107 with a mobile electronics device 110 , such as a mobile phone, can receive the signals while in the room. With the proper processing of the signals 103 , the mobile electronics device 110 can determine the specific location within the building the person 107 is standing. [0024] In a particular embodiment, each room has an audio speaker (i.e., the emitter 105 ) installed that is capable of emitting a combination of high frequency tones (such as in the 20 kHz range). The audio speakers 105 have relatively low distortion in order to prevent audible intermodulation distortion that can occur when two or more high frequency tones are played from the same audio speaker. [0025] Using existing hardware on a mobile device, the mobile electronics device can determine the location at “room (or, more generally, location) resolution” by detecting combinations of high frequency tones in the room being served by the emitters 105 . Soundwaves, especially high-frequency sound waves, do not travel well through solid walls or around corners, so the tones (i.e., signals 103 ) in the rooms are significantly louder than tones from neighboring rooms in most situations. [0026] In some embodiments, processing in the mobile electronics devices 110 can detect the most prominent tones in the room simply by extracting peak values of the power spectrum, as provided, for example, by a Fast Fourier Transform (FFT). Because of multipath effects caused by room acoustics, Doppler effects caused by movement of the mobile electronics device 110 , and general noise within the room, the mobile electronic device 110 can get a more accurate reading by integrating the FFT power spectrum over time, which greatly reduces the effect of those problems and gives a more clear reading of which tones are present in the room. This integration only needs to take place over a few seconds. The integration also prevents “bouncing” and confusion when the mobile electronic device 110 transitions from one room to another. [0027] In a particular example, a total of eight different tones can be used as a type of binary indicator of which room the device is currently located. The tones may be separated by at least 250 Hz, or less if appropriate processing is available in the mobile electronics device 110 , as well as being transmitted by emitters and receivers that can perform with sufficient signal separation. With eight different possible tones, a system can treat the tones as a simple eight-bit binary signature, resulting in a possibility of up to 256 different rooms using a bandwidth of 2 kHz (e.g., 20 kHz-22 kHz). Each room may play a different combination of tones. For example, room 1A1 might play tones 20,000, 20,250, and 21,000 Hz, while room 1A2 place tones 20,000, 20,500, 21,000, and 21,500 Hz. [0028] After the mobile electronic device 110 detects which tones are being played in the room, the device 110 can refer to a simple look-up table (not shown) either built into the device 110 or accessible from a server via a network (not shown) to which the device 110 can connect. In this way, the device will know which room it is in or tell a server which room it is in, whichever is more useful to the user and the system. [0029] Continuing to refer to FIG. 1 , although some embodiments may use ultrasonic wavelengths or frequencies, such as 20 kHz to 40 kHz, or a small range therein, such as 20 kHz-22 kHz, or other range suitable for servicing an entire building while not disrupting flow of human activity except possibly in an emergency situation (i.e., using frequencies within an audio range of most people, such as between lkHz and 15 kHz, it should be understood that other forms of signals, such as non-visible optical wavelengths (e.g., infrared wavelengths) may alternatively be used if the mobile electronics device is equipped to receive such wavelengths. [0030] Although the signals 103 may be perceptible by a mobile electronic device 110 , the signals 103 may also be used for security purposes, such as to ensure a computer stays in a given room and does not transfer between rooms. Various techniques may be used to determine the location in which the mobile or stationary electronics devices is, such as through use of a look-up table or calculating a location encoded in the signals 103 , or accessing information corresponding to the received signals 103 through use of a network and a remote server (not shown). [0031] Examples of various signals 103 are described below in reference to FIGS. 6A and 6B . In cases in which a look-up table is used by the mobile electronics device 110 , the mobile electronics device 110 may be configured with the look-up table by a service provider, or the mobile device 110 may obtain the look-up table on a permanent or temporary basis as the mobile device 110 enters the building 100 . The look-up table may be represented as a three-dimensional grid corresponding to floors and rooms on each floor within the building 100 . [0032] FIG. 2 illustrates a person 207 with a mobile electronics device 210 , such as a mobile phone, entering a building 200 via a rotating door 217 . A transmitter 212 transmits a mapping 215 that includes information, such as a table of correspondences, so that the mobile device 210 can convert sensed signals (e.g., signals 103 of FIG. 1 ) into an indication of a location within the building 200 . The mapping 215 may be simple data that can work within other applications within the mobile electronics device 210 or may be a self-operating app (i.e., application configured to operate on a smart phone) that self-configures on the mobile electronics device. The mapping 215 or corresponding app may timeout after a certain period of time or after some length of time the mobile electronics device 210 is no longer within range of any of the signals providing locations within the building 200 . Alternatively, the transmitter 212 or a transmitter outside the building (not shown) may cause the app to solve-terminate for security purposes. [0033] FIG. 3 is a table 316 that illustrates correspondences between rooms 319 and tones 321 . In the example table of correspondences 316 , there are eight tones ranging from 20 kHz to 21.75 kHz, separated by 250 Hz. The rooms 319 may have an emitter (e.g., audio speaker) that can emit the frequencies with sufficient fidelity that a transducer/receiver in an electronic device, such as a mobile electronics device, can accurately receive the frequencies and perform processing to make a determination as to which room the electronics device is currently located. [0034] In the example table correspondences 316 , a first row 320 a indicates that a signal generator/emitter pair in room 1A1 has three frequencies turned ON, namely tones 1 (200 kHz), tone 2 (20.25 kHz), and tone 5 (21.0 kHz), while all others are OFF. In the next row 320 b , for room 12A, tones 1, 3, 5, and 7 are ON. For the remainder of the rooms, a building manager can configure a controller to cause a signal generator to generate signals that cause the emitter to emit the frequencies of the respective tones such that each room is unique from each other room. Alternatively, there may be reuse of frequencies, but it may be useful that rooms are separated enough in terms of their audio frequencies such that there is little to no crosstalk between adjacent rooms so that the mobile electronics devices or other electronics devices can distinguish their locations effectively. [0035] FIG. 4 is a block diagram of an indoor facility network 425 . The network 425 includes a controller 430 , data storage 435 that stores a mapping 416 with parameters 420 . The mapping may include parameters that can be used by a signal generator 442 that generates a location-unique drive signal 444 that causes an emitter 405 to produce a unique signal 403 for a particular room, such as room 1A1 with respect to, for example, an adjacent room, such as room 1A2 or 1B1 ( FIG. 1 ). The parameters 420 may be stored in a memory 442 that the signal generator 440 uses until receiving different parameters or otherwise programmed. [0036] The controller 430 may be accessible to a facility manager to reconfigure the network such that improved performance by mobile electronics devices is achieved. For example, if mobile electronics devices (not shown) find that there is ambiguity between two rooms as a result of having signals in adjacent rooms (or hallways) too close in frequencies, specifically the frequencies or modulated frequencies emitted composing the signals within the rooms are too similar to those by adjacent emitters, then the facilities manager can simply change the mapping 416 by way of changing the parameters for 420 , such as via a computer interface (not shown) operatively coupled to the controller 430 . It should be understood that the parameters can be in the form of signal parameters, such as frequency, amplitude modulation, frequency modulation, or other forms of modulation that can be used to cause the emitter to vary a signal parameter that can be sensed by a transducer on a mobile device to determine location within a building. [0037] The indoor facility network 425 is merely an example of a network. It should be understood that the signal generator 440 and emitter 405 may be in a standalone box mounted on a wall, configured in light fixtures, positioned in surveillance cameras, or otherwise made available for positioning in a fixed location in the building. It should be understood also that the term “fixed location” may mean that the emitter is mounted securely to a wall or fixture or that the emitter 405 is simply placed in a room, such as connected to an external port to a computer bus (e.g., USB port) that does not change its position relative to the structure of the indoor facility. In an event the signal generator/emitter is moved from one room to another and causes reduced system performance, the facility manager can simply modify the parameters 420 in the data storage 435 , as previously described. [0038] FIG. 5 is a block diagram of a mobile electronics device 510 . The mobile electronics device 510 includes a transducer 545 configured to receive signals 503 from the emitters, such as the emitter 400 and 405 of FIG. 4 . The transducer 545 may be a standard microphone found in all mobile phones, so long as the microphone can sense and distinguish frequencies emitted by the emitters with the frequency spacing, as provided in some embodiments. For example, in the case of ultrasonic emitters, the standard microphones of mobile phones must be able to sense frequencies in the 20 kHz range, and possibly as high as 40 kHz, and in some cases with 250 Hz spacing. Alternatively, the mobile phones may be specially equipped or have the internal electronics sensitive to frequencies at much higher ranges, such as in the 100 kHz range or higher. As mentioned above, the transducer 545 may, alternatively, be an optical transducer that can sense optical wavelengths that may or may not be in the visible spectrum, for example, in the infrared spectrum. [0039] The transducer converts the signal 503 to a transduced signal 547 that is sent to a receiver 550 . The receiver converts the transduced signal 547 into a representation of a signal 551 . The representation of the signal 551 may be representations of frequencies, such as 20 kHz, 20.5 kHz and 21 kHz. These representations 551 are sent to a mapping module 555 , that may include or access a table of correspondences 516 . Based on the data in the table of correspondences 516 , the mapping module 555 can report an indication of location 557 within the indoor facility. [0040] The receiver 550 may include special processing to improve performance of the mobile electronics device 510 in determining its location within the indoor facility. For example, the receiver 550 may include a noise reduction module that can use, for example, Fast Fourier Transforms (FFTs) and integration of power spectrum to reduce noise effects, such as fan noise within a room or emitted signals from adjacent rooms. In one case, for example, the processing within the receiver 550 can detect a highest peak within a spectrum under analysis to determine the most likely signal from the emitter in the room. Based on that selection, the mapping module may be presented with data, possibly formed of multiple frequencies, in order to determine the indication of location 557 within the indoor facility. [0041] The receiver 515 may also include a Doppler compensation module 554 . As described above, the Doppler compensation module 554 may include processing that compensates for movement of the mobile electronics device to identify more accurately which frequencies have been sensed by the transducer 545 . For example, if the mobile electronics device is moving within a room, there may be a sensed frequency shift that causes one frequency to appear to be a higher or lower frequency. If the frequencies that compose the signal within a room are very closely spaced, such as less than 250 Hz, then frequencies may appear to be other frequencies due to the movement. By compensating for Doppler shift, such ambiguities caused by movement can be reduced or eliminated. [0042] It should be understood that other forms of processing may also be used in the receiver 550 . Further, it should be understood that raw data from the transducer 545 (i.e., the transduced signals 547 ) may be transmitted by the wireless device to a server for the processing, such as the noise reduction or Doppler compensation to conserve on battery power of the mobile electronics device. [0043] FIG. 6A provides an image of a spectrograph of what two tones being played look like as a user walks around a room with an emitting device therein. In the spectrograph, the user with the device started at a greater distance from the sound emitting device (about 30 feet) and walked around the room until the user ended up very close to the sound emitting device. The area where the lines representing the respective frequencies of the signal looks dim is because the signal was weaker due to distance, and the areas where their frequency content looks smeared is the Doppler effect taking place when the user moves quickly. There is no special noise reduction taking place in the spectrograph of FIG. 6A . [0044] FIG. 6B is a set of graphs 660 that illustrates an embodiment in which the frequencies are not fixed frequencies, but are frequencies (i.e., carrier waves) modulated in some manner. By using modulation, rather than having many frequencies used to provide distinguishing information for a mobile electronics device to use in determining its location within a building, the system can use fewer frequencies but modulate those frequencies in a manner that can be sensed and received by the mobile electronics device. [0045] The difference between the fixed frequency embodiment and modulation embodiments is that more processing must be performed on both the transmitter and receiver sides for the modulation embodiments. However, if such processing is not a significant cost, such as in terms of processing or power consumption, then the modulation embodiments may be useful to employ, particularly in cases of many rooms within a building. The modulation embodiments may also be effective if emitters cannot support many frequencies, such as eight frequencies within a 2 kHz frequency band at 20 kHz, or emitters that can emit one or two frequencies and do well with modulation. [0046] Continuing to refer to FIG. 6B , a first time chart 665 a (for room 367 ) that modulates a 20 kHz carrier wave is shown. In this example embodiment, there is a start of frame 670 that allows a mobile electronics device to know a beginning to start looking for modulations. Here, the modulations are on-off modulations 675 a , 675 b . In the example first time chart 665 a , the modulations occur at T=3 and T=6. The on-off modulation times can be configured by a facilities manager, or the system can be self-configuring at a system level based on some form of reporting by mobile electronics devices as they move from room to room. [0047] In the second time chart 665 b , (for room 7F2), there is similarly a start of frame 670 that is followed in time by on-off modulations 675 c , 675 d . In this case, the modulations are made to a carrier wavelength of 20.5 kHz. [0048] Again, it should be understood that any form of modulation may be used. The example of FIG. 6B is merely provided as a convenient example. [0049] In accordance with an embodiment of the invention, the signals emitted at multiple fixed locations within an indoor facility can be emitted without any necessary concurrent emitting of wireless network signals. Mobile devices may be localized without any reference to a wireless network. Instead, localization may be based only on the human imperceptible signals, such as ultrasonic signals and/or non-visible optical wavelength signals. [0050] It should be understood that embodiments or aspects of the present invention may be performed in hardware, firmware, or software. For example, the processes associated with performing FFTs, look-up table activities, and other activities described herein, may be performed on mobile electronics devices through use of software. The software may be any form of software that can operate in a manner consistent with the example embodiments described hereinabove. The software can be stored on any non-transient computer-readable medium, such as RAM, ROM, or any magnetic or optical media known in the art. The software can be loaded and executed by a processor to perform operations consistent with embodiments described above. [0051] Presenting an indication of the location of the mobile electronics device can be done in various forms, such as on a display of the device, through audible notification, visual notification, electronic messaging, and so forth. Further, applications such as security guard monitoring (i.e., ensuring rounds are being made), user notification of safe and unsafe rooms or hallways within a building during an emergency, security clearance monitoring (e.g., the electronic device issues an audible tone if the device is carried into a restricted access area), or providing a guided tour, such as in a museum. Once the system has been configured, the applications are plentiful. [0052] While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
Because GPS does not work indoors, mobile electronics devices that use GPS for activities do not work inside a building. An embodiment of the present invention is uses ultrasonic tone generators in each room. The ultrasonic tone generators can be built into cameras or separate devices. Each device may emit a unique tone that has a high enough frequency that most people cannot hear the frequency or combination of frequencies. Using a built-in microphone on a mobile device, the incoming audio may be analyzed in the frequency domain to determine the loudest tone above the human hearing threshold. This tone may be mapped to a specific room that can then be sent to the mobile electronics device to perform any location-aware actions.
7
FIELD OF THE INVENTION [0001] The invention relates to a method for converting a first input data corresponding to a property of a first material to a second type of data corresponding a property of a second type of material, the first data being an input and the second data being an output, and the relationship between the value of the first and the second data being predetermined. More specifically, the invention relates to a method of converting a first type of concrete reinforcing material data to an equivalent quantity of concrete reinforcing fibers. Even more particularly, the invention relates to a method of converting concrete reinforcing material data such as steel rebar or steel mesh data into an equivalent quantity of fibers, such as synthetic or steel fibers, for reinforcing concrete. BACKGROUND OF THE INVENTION [0002] Reinforced concrete is known. [0003] It is known to reinforce concrete with steel rebar, with mesh, or with concrete reinforcing fibers, such as steel or synthetic fibers. The fibers may be synthetic microfibers or macrofibers, for example. [0004] Concrete reinforced with fibers is termed fiber reinforced concrete (FRC). Fiber reinforced concrete (FRC) is used for controlling and reducing the initiation of and propagation of cracks in concrete. [0005] Lightly reinforced concrete slabs are concrete slabs suitable for low static and dynamic load applications such as concrete floors in shopping centers, cultural centers, showrooms, trade fairs, and the like. [0006] Known reinforcement of lightly reinforced slabs, such as by the use of steel rebar or mesh is often unsatisfactory. Conventional reinforcement of lightly reinforced slabs is often unsatisfactory because the steel rebar or mesh in conventional slabs is usually provided in the lower portions of the slab and, in particular, below the top one-third of the slab. That conventional placement of steel rebar and mesh reinforcing is significant because it is in the top one-third of the slab where such reinforcing would actually be most beneficial. [0007] The conventional steel rebar or mesh that is added in the bottom two-thirds of the slab and, indeed, often in the bottom one-third of the slab, provides some measure of control of cracking of the slab at the surface. [0008] However, there is a need to reinforce lightly reinforced slabs to avoid the cracks at the surface that appear in conventionally reinforced slabs. [0009] Known patents for concrete reinforcing steel fibers include: [0010] U.S. Pat. No. 6,045,910 to Lambrechts; and [0011] U.S. Pat. No. 6,269,602 to Thooft et al. [0012] Known indicating devices include: [0013] U.S. Pat. No. 5,678,862 to Hughes et al.; and [0014] U.S. Pat. No. Des. 370,494 to Hughes et al. [0015] Known examples of devices which indicate inputs and outputs include: [0016] Dean Foods 401(K) Plan “Scorecard/Crunching the numbers”, ©2002 MFS Investment Management®, MFS Fund Distributors, Inc., Boston, Mass. 02116, USA, (DEAN-SR-04/02/12M); [0017] Wachovia “Traveler's Check Verification”, ©2002 Abagnale & Associates (800-237-7442); and [0018] Union Wire Rope “Ton-Mile Indicator”, Union Wire Rope/Division of Wire Rope Corporation of America, Incorporated, St. Joseph, Mo. 64501, USA, undated. OBJECTS AND SUMMARY OF THE INVENTION [0019] It is an object of the invention to overcome the drawbacks of the known methods of reinforcing concrete slabs, such as lightly reinforced slabs. [0020] Another object of the invention is to increase the tensile strength of lightly reinforced slabs. [0021] A further object of the invention is to control the appearance of undesirable and high-maintenance cracks in concrete. [0022] Yet another object of the invention is to provide a method of calculating an appropriate quantity of concrete reinforcing fibers to use in a fiber reinforced concrete (FRC) slab. [0023] Another object of the invention is to provide a method of calculating an appropriate quantity of concrete reinforcing steel fibers to use in a steel fiber reinforced concrete (SFRC) slab. [0024] Yet another object of the invention is to provide a method of determining an appropriate equivalent fiber dose which is established using the spacing theory. [0025] Another object of the invention is to determine the appropriate equivalent fiber dose corresponding to rebar or mesh reinforcing by equating the area of steel provided by the rebar or mesh to the area of material provided by the quantity of fibers to be determined. [0026] Another object of the invention is to determine an equivalent fiber dose corresponding to a given rebar or mesh reinforcing by equating the moment capacity of a fiber reinforced concrete (FRC) section to the moment capacity of a given rebar or mesh reinforced section. [0027] A further object of the invention is to provide a method which is a combination of the three methods described immediately above to arrive at equivalent fiber dosages equivalent to conventional steel methods. [0028] Yet another object of the invention is to provide a method of determining whether the slab to be reinforced is a lightly reinforced concrete slab, then determining an appropriate (e.g. desired) quantity of fiber to be used by the provision of a calculator, the calculator including a first rebar or mesh data input field and a second fiber output field, so that the user may readily determine a corresponding quantity of fibers equivalent to a given input of steel rebar or mesh. [0029] Another object of the invention is to provide such a calculator in the form of a hand-held device having preset input and output values based on previously performed calculations. [0030] Another object of the invention is to provide a hand-held calculator of the above type that is in the form of one physical element movable relative to another physical element, so as to readily indicate data inputs and outputs. [0031] Yet another object of the invention is to provide a hand-held calculator of the above type in the form of two pieces of relatively movable flat material, such as two pieces of cardboard. [0032] A further object of the invention is to provide a method of calculating concrete fiber reinforcing doses, equivalent to conventional concrete reinforcement, such as rebar and mesh, and which concrete fiber reinforcing doses can be calculated for synthetic as well as steel fibers. [0033] Another object of the invention is to provide a hand-held calculator of the above type in the form of an electronic calculator with previously calculated outputs corresponding to inputs entered by a user. [0034] In sum, the invention is directed to a method for converting a first type of concrete reinforcing material to an equivalent quantity of concrete reinforcing fiber for designing a reinforced concrete slab. The method may include determining whether a slab to be reinforced is a lightly reinforced slab on which loads to be carried are not excessive; and then using the spacing theory to get a minimum fiber dosage for a given concrete slab thickness, if the slab to be reinforced is a lightly reinforced slab. The user then uses an equivalent area of material calculation to determine a proper fiber dosage, if the minimum fiber dosage for a given concrete slab thickness is insufficient to give a residual strength factor greater than 30 percent. If the minimum fiber dosage for a given concrete slab thickness is sufficient to give a residual strength factor greater than 30 percent, then the user uses an equivalent moment capacity calculation to determine a proper fiber dosage. A tabulation in the form of a fiber reinforced concrete design calculator may be provided, such a fiber reinforced concrete design calculator including a first input field including a first set of data corresponding to a first type of concrete reinforcing material, and a first output field including a first set of data corresponding to a first type of concrete reinforcing fibers. [0035] The above inventive method includes determining the equivalent fiber dosage for synthetic as well as steel fibers. [0036] It will be appreciated that relative terms such as up, down, vertical, horizontal, left, and right, are for convenience only and are not intended to be limiting. [0037] The term design refers to engineering design, independent of aesthetic considerations. BRIEF DESCRIPTION OF THE DRAWINGS [0038] FIG. 1 is a top perspective view of a calculator according to the invention for performing a method according to the invention, the calculator showing inputs and outputs; and [0039] FIG. 2 is a top perspective view of the inventive calculator of FIG. 1 , shown in a moved position indicating further inputs and related outputs. DETAILED DESCRIPTION OF THE INVENTION [0000] Three Methods to Determine The Appropriate Equivalent Fiber Dose: [0040] The inventive method and calculator may be understood by first considering the underlying methodology. [0000] Method 1 [0041] 1. A minimum quantity of fibers is established using the spacing theory (See Mckee, D.C., “The Properties of an Expansive Cement Mortar Reinforced with Random Wire Fibers”, Ph.D., Thesis, University of Illinois Urbana, Urbana, Ill., USA 1969). The theory describes how to calculate the number of steel fibers required to ensure complete coverage using the following formula: SF dose=[1÷(0.58× l f ) 3 ]÷[4÷(π d f 2 l f )×7850] [0042] Where, l f =fiber length d f =fiber diameter SF dose=steel fiber dose. Method 2 [0045] 2. A quantity of steel fibers is calculated by equating the area of steel provided by rebar or mesh to the area of steel provided by steel fibers. The equivalent cross sectional steel area is based on a method by Soroushian and Lee (See Soroushian and Lee, “Distribution and Orientation of Fibers in Steel Fiber Reinforced Concrete”, ACI Materials Journal 87-M44, 1990) and determines the number of fibers crossing a plane per unit area using the following formula: SF dose= A s ×13200÷(α× t× 12) [0046] Where, A s =conventional steel area t=slab thickness α=fiber orientation factor SF dose=steel fiber dose. Method 3 [0050] 3. A quantity of steel fibers is calculated by equating the moment capacity of a steel fiber reinforced concrete section to the moment capacity of a conventional rebar or mesh reinforced section. The method uses yield line analysis and is described in TR-34 (See Technical Report 34 (TR 34) “Concrete Industrial Ground Floors—A Guide to Their Design and Construction”, The Concrete Society, 1994). The quantity of steel fibers is calculated using the following formula: M o =M n +M p +[1+ R 10, 50 ]×f r ×S Where, f r =plain concrete modulus of rupture (4,000 psi assumed) S=section modulus R 10, 50 =SFRC residual strength factor M n =negative moment resistance of slab M p =positive moment resistance of slab [0056] The residual strength factor is directly related to the dose of a specific steel fiber type and the concrete compressive strength. This relationship is determined from laboratory scale beam tests performed in accordance with ASTM C 1018. [0000] How To Specify Steel Fibers, such as Dramix® Brand Steel Fibers (Dramix® is a Registered Trademark of NV Bekaert SA, Zwevegem, Belgium) [0057] For Type I Fibers: [0058] Steel fibers shall meet the requirements of ASTM A 820 Type I. Steel fiber content at placement shall not be less than [dosage rate] lb/yd 3 of Dramix® [fiber designation]. [0059] For Type V Fibers: [0060] Steel fibers shall meet the requirements of ASTM A 820 Type V. Steel fiber content at placement shall not be less than [dosage rate] lb/yd 3 of Wiremix®. (Wiremix® brand fibers is a registered trademark of NV Bekaert SA, Zwevegem, Belgium) [0000] Efficiency [0061] A tabulation of the quantity of fibers, such as steel or synthetic fibers, which equal certain configurations of rebar and mesh, may be set forth in a calculator 10 described in detail below. The spacing theory establishes the minimum dosage. [0062] The equivalent area of steel method is used when the dosage of steel fibers, for example, is not sufficient to produce a residual strength factor greater than 30%. [0063] The equivalent moment capacity method is used when the dosage of fibers, such as steel fibers, suffices to produce a residual strength factor greater than 30. [0064] It must be emphasized that when using FRC, SFRC, mesh or rebar for lightly reinforced slabs, control joint dimensions must be chosen using PCA (Portland Cement Association, Washington, D.C. 20036, USA; http://www.cement.org) and ACI (American Concrete Institute, Farmington Hills, Mich. 48331 USA; http://www.aci-int.org) guidelines or other local code requirements assuming no reinforcement is present. [0000] Calculator Embodying the Method [0065] FIGS. 1 and 2 illustrate an embodiment of a tabulation of reinforced concrete material specification or design data in the form of a calculator 10 according to the inventive method described above. [0066] Calculator 10 may be in the form of a chart, or in the form of a first element or cover 12 and a second element or insert 14 which is movable relative to first element or cover 12 . [0067] As will be readily appreciated the various data fields and pieces of data shown in the data fields may be calculated in advance, as shown, for ease of use by the user of calculator 10 . [0068] For ease of use, first element 12 may include a front panel 16 and a rear panel 18 joined together by a side portion 22 and an optional further side portion 24 . Conveniently, first element 12 may be in the form of a sheet of plastic or cardboard, and a connection or side or joint 22 may be a fold in the cardboard which joins face 16 to rear 18 and envelops slidable slot element 14 . A partially removed portion 26 may be provided so that a portion of element 14 may be readily grasped by a finger of a user. [0069] Calculator 10 may include a first data field 30 corresponding to a first type of concrete reinforcing material, such as the illustrated “Welded Wire Fabric”. Data field 30 may include one or more subfields 32 , 34 , 36 , and 38 , for example. Subfield 32 may correspond to a first type of welded wire fabric; e.g. Type A, as shown. Field 30 may include collectively, for example, different types of 6″×6″ welded wire fabric. Type A welded wire fabric may be W1.4/10 gage 6″×6″ welded wire fabric. Subfield 34 Type B welded wire fabric may be, for example, W2/8 gage 6″×6″ welded wire fabric. [0070] A further data field 40 may correspond to a quantity (e.g. in pounds or kilograms) of a second type of concrete reinforcing material. Individual pieces of data in individual subfields may include data 42 , 44 , and 46 , as shown. [0071] This type of data 42 , 44 , 46 may be considered an output based on inputs (e.g. concrete slab specification data) described above and below. For example, a further data field 60 may include various types of concrete reinforcing fibers, such as synthetic or steel fibers, for use in producing fiber reinforced concrete (FRC), such as the illustrated subfield 62 showing “Type P Fiber” and further data field 64 illustrating “Type Q Fiber”. [0072] Yet another input data field 70 may be provided including subfields 72 , 74 , 76 , and 78 , for example, corresponding to yet another basic type of reinforcing material, and subtypes within that basic type shown in the various subfields 72 - 78 . For example, data field 70 may be considered an input data field corresponding to 4″×4″ welded wire fabric, or, indeed, additional types of 6″×6″ welded wire fabric, in the case where data field 30 corresponds to 6″×6″ welded wire fabric. Again, discrete data points may be shown in an output data field 80 , such output data field 80 corresponding to quantities (e.g. pounds or kilograms) of another type of concrete reinforcing material, such as the illustrated different types of fibers shown in data field 90 . [0073] Still further, additional concrete construction specifications, such as the type, thickness, expected static and dynamic loads, joint spacing, and the like may be provided in a concrete slab specification data field 100 , as shown. [0074] A subfield or data field 102 may designate slab thickness (in inches or millimeters), a subfield 104 may conveniently provide a pre-calculated conversion of square feet per cubic yard or square meters per cubic meter, a subfield 106 may designate joint spacing (e.g. in feet or meters). In addition, a subfield 108 may be used for indicating an expected maximum axle load (in kips or kiloNewtons), a data field 110 may indicate an expected maximum rack load (in kips or kiloNewtons), and a further data field 112 may indicated an expected maximum uniform load (in kips per square foot or Newtons per square millimeter). [0075] A piece of input data 116 , such as the “5.5” shown in FIG. 1 , may correspond to an expected design slab thickness of 5.5 inches. [0076] If the user contemplated constructing a 5.5 inch slab, the user could readily determine that such a 5.5 inch slab would cover 58 square feet for every cubic yard of concrete that the user poured, as designated by reference number 118 . [0077] Additional data field or subfield 120 may include additional pieces of input or output data 122 and 124 , depending on one's point of view. That is, it may be appreciated that with an expected slab thickness of 5.5 inches and an expected maximum uniform load of 1.15 kips per square foot (ksf) as shown by data 126 , one may likewise expect a maximum rack load of 5.9 kips could be carried by the 5.5 inch slab, as indicated by data 124 . [0078] Given those expected inputs in fields 116 and 120 , and related subfields, the user may readily determine that if the user had anticipated using Type A welded wire fabric of field 32 , then the user could use instead an equivalent quantity of Type Q fibers as shown in data field 64 , the equivalent quantity being 25 pounds of Type Q fiber as indicated by data 132 . [0079] If, instead, the user wanted to know what the equivalent quantity of Type R steel fiber would be, the user could readily determine that 30 pounds of Type R steel fiber would correspond to 25 pounds of Type Q fiber. The 30 pounds of Type R steel fiber being designated 134 and the 25 pounds of Type Q fiber being designated 132 . Quite simply, as will be readily apparent, the user need simply to read down in the column below data field 32 and read across to the right in data field 60 and the intersection between the corresponding vertical and horizontal lines, respectively indicate the data point in question. As yet another example, if one reads down vertically in the column corresponding to subfield 32 and if one reads horizontally across to the right in the row corresponding to Type P fiber data subfield 62 , the intersection will read “17”, 17 corresponding to 17 pounds of Type P fiber being equivalent (i.e. yielding an equivalent strength to the reinforced concrete) to the Type A welded wire fabric. [0080] The subfields or fields 70 , 80 , 90 , and the like may be used in an analogous fashion. [0081] A field 140 may be provided as an informational field, such as the illustrated field 140 showing “RACK LOADS (kips) [definition]” indicating that the definition of rack load could be provided on calculator 10 itself, for ready reference by the user. [0082] Still further, in use, the user may desire, based on expected slab loads, that a slab thickness of 7 inches is required. Please see FIG. 2 in which 156 designates a 7 inch slab thickness. [0083] In use, it will be seen that a user may readily move second element or insert 14 in the direction of an arrow 150 for locating further pieces of data in different data fields, such as the illustrated slab thickness of 7 inches being shown as data input 156 . Alternately, one might consider the expected maximum uniform load of 1.30 ksf as the expected maximum load, the expected maximum load being designated 158 . The slab thickness of 7 inches suffices to carry that maximum expected uniform load of 1.30 ksf, assuming the maximum axle loads and rack loads are at most the maximum loads indicated by data points 162 and 164 , respectively. [0084] Thus, once the slab thickness has been designated, the user can again, as described above, readily determine that 30 pounds of Type R steel fiber (designated 166 ) is equivalent to a given quantity of Type A welded wire fabric, 25 pounds of Type Q fiber (designated element 168 ) is equivalent to that same Type A welded wire fabric, and 17 pounds of Type P fiber (designated 172 ) is likewise equivalent to that given quantity of Type A welded wire fabric. The given quantity of Type A welded wire fabric may be 6″×6″ steel wire mesh of a given gage, for example. [0085] It will thus be seen that the inventive method and related calculations are readily calculated in advance and put in a form easily usable by the user. The form of tabulating the results of the inventive method may be calculator 10 , as shown, with two relatively moveable parts, one slidable relative to the other; i.e. cover 12 being movable relative to insert 14 , and vice versa. [0086] The relatively moveable components may be in the form of other shapes, such as discs and the like, any shape including data fields which may be readily aligned and displayed. [0087] Additional data fields are expected, such as metric units (SI units) being shown on cover 16 , or on the rear 18 , for example. The English units and metric units may be aligned so that if one aligns a desired English unit, one may readily look at another exposed field on the front or on the rear of the device, and immediately see the equivalent metric unit without further manipulation of the calculator. [0088] It is likewise contemplated that the calculator be in an electronic form, with the calculations already performed, or the algorithm stored in a dedicated chip, for example, so that the user simply needs to enter a slab thickness and expected load, for example, and the calculations in accordance with the inventive method are carried out to reveal displayed results in one or more electronic calculator displays that show equivalents in wire mesh and fibers, such as synthetic and steel fibers. It will be appreciated that various designated buttons could be provided on such a calculator so that the user need simply to press buttons labeled slab thickness, synthetic fibers, steel fibers, types of steel fiber, microfibers, macrofibers, steel mesh, rebar, and the like. [0089] While this invention has been described as having a preferred design, it is understood that it is capable of further modifications, and uses and/or adaptations of the invention and following in general the principle of the invention and including such departures from the present disclosure as come within the known or customary practice in the art to which the invention pertains, and as may be applied to the central features hereinbefore set forth, and fall within the scope of the invention or limits of the claims appended hereto.
Method for converting a first type of concrete reinforcing material to an equivalent quantity of concrete reinforcing fibers for designing a reinforced concrete slab. Fibers may be steel or other materials. User determines whether a slab to be reinforced is a lightly reinforced slab; and then uses spacing theory to get a minimum fiber dosage for a given concrete slab thickness, if the slab is a lightly reinforced slab. User then uses an equivalent area of steel calculation to determine proper fiber dosage, if the minimum fiber dosage for a given concrete slab thickness is insufficient to give a residual strength factor greater than 30 percent. If minimum fiber dosage for a given concrete slab thickness suffices to give a residual strength factor greater than 30 percent, then user uses equivalent moment capacity calculation to determine a proper fiber dosage. Concrete design calculator may incorporate method and values.
4
FIELD OF THE INVENTION A detector for thermal neutrons, which can be made in a compact shape and size. BACKGROUND OF THE INVENTION Uncharged nuclear particles (neutrons and gammas) are commonly detected in a useful form (i.e., an electric impulse) by first converting them to charged particles via an atomic or nuclear interaction, and then detecting the ionization trail generated by the (secondary) charged particle. Devices designed for uncharged particle detection have been relatively large due to the necessary volume of material needed for particle conversion, the array of photomultiplier tubes, and/or cryogenic cooling apparatus. These complications have precluded the development of a small and compact detector. This invention enables a very efficient detector to be manufactured at a reasonable cost, which can be made so small in size as to fit in a pocket, and which can operate at ambient temperatures for an indefinite length of time with minimal maintenance. Such devices as photomultiplier tubes and any kind of cryo system are unnecessary. The basic concept of this invention is that, after efficiently converting the thermal neutron to an α particle using thin B 10 , a charged coupled device (CCD) can be used to detect the charged particles. Further, in order to reject false alarms and to permit detection to very low neutron flux levels, a stack of CCD arrays can be arranged so that their output can be processed to disregard higher energy particles of no interest to the intended measurements. Classically a CCD is used to detect visible or IR photons. However, it is also a good charged particle detector, but with poor energy resolution. Although semiconductor materials (Ge, Si) which are used in CCDs have themselves been employed as radiation detectors, the CCD has not generally been used for charged particle detection because it provides no or poor energy resolution for KeV-MeV energy charged particles. This is the major reason why CCDs have been developed as highly sensitive visible light detection and imaging devices, but not for detection of charged particles. Interaction of charged particles with CCDs is regarded as a source of noise, not something to be detected or measured. It is an object of this invention to make use of the extreme and well-understood sensitivity of the CCD to ionizing radiation for the detection of thermal neutron reaction products even at low neutron flux levels. Importantly, where a CCD is used for this purpose, neither energy resolution nor imaging is required. Thus simplified, CCD technology enables the construction of a compact, fully solid state, room temperature, neutron detector which is capable of registering nearly every incident neutron. This device is also amenable to discrimination against energetic background radiation. While a single CCD pixel will stop alpha particles from a neutron of interest, cosmic rays, energetic gamma particles, and charged particles from other sources will penetrate several layers of CCD arrays. This will cause activation in several layers of CCD arrays. Coincidence measurements between adjacent arrays can be used to discriminate these types of particles or rays from those of interest to this detector, thereby to reject false alarms, and to permit detection to very low neutron flux levels. Also, less energetic charged background particles, as, for example, from radon decay, can be eliminated by encasing the detector in a material which will stop all but the most energetic charged particles from entering the detector, but will have no effect on the neutrons which are to be detected. A very high degree of discrimination is thereby attainable. BRIEF DESCRIPTION OF THE INVENTION A detector for thermal neutrons according to this invention is a layered structure, alternating between boron slabs (layers) and CCD arrays. Rectangular CCD arrays are employed, in accordance with conventional practice, and the boron slabs are contiguous to the CCD arrays. According to a preferred construction, the boron slabs may be deposited on the CCD arrays. The arrays and slabs are brought firmly together to form a composite structure. A CCD indicates a charged particle by providing an electric impulse in the array. These impulses are detected by conversion to a suitable output, the preferred example being a video output on an LCD display. Conventional connections to the CCD array provide the necessary power and timing pulses, which connections and related equipment can be small and portable. Control of the operation and analysis can readily be arranged through a key pad. Suitable output devices are not limited to video. Disk storage, and audio outputs are also useful for field use. The type selected depends on the intended utilization of the detector, its being selected for most convenience in use. The above and other features of this invention will be fully understood from the following detailed description and the accompanying drawings, in which: BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an exploded perspective view of the presently-preferred embodiment of a detector according to this invention; and FIG. 2 is a schematic view showing the detector of FIG. 1 incorporated in circuitry for its utilization. FIG. 3 is an edge view of a modified embodiment of the invention. DETAILED DESCRIPTION OF THE INVENTION FIG. 1 is an exploded view of the detector 10 itself. It comprises a plurality of boron slabs 11, each adherent to a CCD array 12. These are pressed into a solid block as best shown in FIG. 2. Cells 13 (called pixels) are schematically shown in FIG. 1. These cells register the charged particles which impinge on them and generate an electrical impulse when such impingement occurs. Leads and connections (not shown) are connected to the CCD arrays according to conventional practice in the utilization of CCDs. The materials of construction and the dimensions of thickness of the elements of this detector are of considerable importance. It is known that He 3 and B 10 are two stable isotopes with large thermal neutron absorption cross-sections, and which provide a charged particle output. Helium has the larger cross-section of the two, but its incorporation into a detector involves many problems of its own. Therefore the use of boron is preferred and is used in this invention. As the term "boron" is used herein, it means either pure boron in its naturally occurring isotope ratio (80% B 11 , 20% B 10 ), pure boron enriched with B 10 , pure B 10 (or very highly enriched B 10 ), tetra-boron carbide (B 4 C, which is a black solid with density 2.52 g/cm 3 ), and boron nitride (BN). BN is a common semi-conductor material, but it provides less sensitivity because it has a substantially lesser boron density. Accordingly, pure boron or pure boron enriched with B 10 are the preferred materials for the slabs, although the term is intended to include all of these examples. It is preferred to utilize highly enriched solid B 10 , whose density is 2.17 g/cm 3 . As to the dimension of thickness of the slab, consider that the mean free path of a thermal neutron in solid B 10 is 0.0019 cm. It follows that a thickness of about 10 -2 cm of B 10 will stop essentially every thermal neutron. However, after the thermal neutron is absorbed, at least one of the reaction products (a charged particle) must escape from the slab in order to be detected. The pertinent reaction products have the following energies: α=1.776 MeV Li 7 =1.015 MeV The α particle mean range in solid boron is about 6×10 -4 cm, which is only about 1/16 of the thickness needed to stop essentially every thermal neutron. The Li 7 mean range is about 2×10 -4 cm. It follows that if one uses a slab thick enough to stop all thermal neutrons, almost none of the charged particles that are produced in it can escape to be detected. As a consequence, the detector would not work if sufficient boron thickness is used in a single slab to stop essentially all thermal neutrons. However, if instead the same total necessary thickness of boron is provided in a substantial number of slabs of lesser thickness, a workable detector can be devised. If, for example, at least 50 B 10 slabs (11), each about 2×10 -4 cm thick, sandwiched between 51 CCD arrays (12), are employed, then almost every e particle and many Li 7 s produced by the nuclear reaction can escape the boron slabs to strike the CCDs and be detected. The entire device will still contain about 0.01 cm thickness of B 10 , which is enough to stop nearly all thermal neutrons. It will have a reduced sensitivity to fast neutrons, but the advantages of the arrangement vastly exceed this minor disadvantage. If a boron material other than highly enriched B 10 is used, more than 50 layers would be necessary for the same neutron stopping efficiency. Because these thinner slabs are only on the order of about 2 μm thick, the boron can be vacuum deposited on the active side of the CCD array. All of the "boron" examples can be deposited in this manner. The area of the arrays and slabs will be selected to be small enough that the detector will be compact, but still will be large enough to detect desired fluxes in reasonable integration times. A total detector area on the order of about 30 cm 2 is readily comprehended. To make neutrons detectors of various sizes, the slabs and CCD arrays can be abutted edgewise to build up areas of any desired extent. The CCD array will be selected for optimum interaction with the charged particles which the slabs will emit, and for operation at room temperature. For this purpose, a silicon-based CCD is preferred. A CCD is a metal-oxide-semiconductor charge accumulation device. It is meant to collect the charge from electron-hole pairs created by photon absorption. For visible photons, the semi-conductor of choice is silicon. Also, the relatively high Si band gap (about 1.1 eV) permits operation at room temperature for indefinite periods of time. None of the α particles from the reactions in the boron slabs will penetrate very deeply into the silicon. Even an α particle which loses negligible energy in the slab will have a range of only about 6 μm in silicon. It will therefore be absorbed in the surface layer of the CCD. The Li 7 range is even shorter--less than 3 μm. When the α particle (or the Li 7 ) strikes the CCD, it deposits energy by forming electron hole pairs. Minority carrier diffusion into the quantum well region then contributes to depleting the well. The CCD registers this charge accumulation. For typical size pixels, well depletion saturates at 10 5 to 10 6 e-h pairs, corresponding to a total energy deposited of 0.1-1 MeV. Thus the α (or the Li 7 ) will saturate the well. Saturation energy is proportional to pixel area and gate voltage. Charged particle stopping distance is small compared with a typical unit cell size (˜15 μm×15 μm), so all the energy of the α particle deposits in a single unit cell and will be detected. Commercial CCDs are available in a variety of sizes, often with more than 100 elements in each direction, and many of them can be used in this invention. In this invention, the number of pixels is less important than the total active CCD area, which should be as large as possible. Pixels 100 μm×100 μm or larger are acceptable. Special large area arrays can be built if warranted. Typical frame rates are at video speeds--30 frames per second. A simple adder can sum images for 1 sec or more without difficulty, providing good detection probability to fluxes less than 0.1 neutrons/cm 2 /sec. Since imaging is not of concern to this detector, linear CCDs may also be utilized. The utility of linear CCDs would depend on a tradeoff of simpler electronics against increased saturation levels. The neutron detection problem itself imposes no pixel shape constraints. CCD arrays are usually made on a Si substrate about 500 μm thick, and can be fabricated to 200 μm or less at higher cost. Thus the entire device may be made to a thickness of about 1 cm (50 elements×about 200 μm). A nominal 500 μm thickness is required for structural strength considerations, a limitation which is eased in a multi-layered device. If the small boron conductivity (about 5.5×10 -5 mho/m) is a problem, the boron layer 11 can be separated from the CCD 12 by a thin (about 1 μm) dielectric sheet 20 such as polyethylene, as shown in FIG. 3. Neutrons will not be absorbed in the Si CCD arrays themselves. Si density (2.33 g/cm 3 ) is N=5×10 22 nuclei per cm 3 , and the absorption cross section for Si 28 (n,γ)Si 29 is 0.17 barn, giving thermal neutrons a mean free path of about 117 cm, as follows: ##EQU1## Thus, neutrons will be absorbed only in the boron slabs and not in the CCD arrays. In the preferred embodiment of the invention, the following reaction is employed: n+B.sup.10 >α+Li.sup.7 This reaction is selected because of its large cross-section. However, the invention is not limited to the use of that reaction, instead, although they will not be preferred, a suitable reaction may be considered more generally, the above being the preferred selection, as follows: n+(low Z stable nucleus)-C+(residual charged nucleus). For example, another suitable reaction within the generally acceptable reactions is: n+Li.sup.6 >T+He.sup.4, where T is a triton. In the above reactions, C is any light charged particle, examples being a proton, deuteron, triton, He 3 and α. In an alternate configuration, one could implant boron directly in the active Si depletion region, allowing very direct conversion of neutrons to accumulated charge within a CCD. This usually will not be preferred. In yet another embodiment, the entire layered device is manufactured as a single unit, depositing Si with the conducting gates and insulating layers of the CCD, with alternating layers of boron. This integrated unit would be especially attractive, because the Si substrate could then be kept thin (on the order of 50 μm), thereby allowing back illumination of the CCD as well, increasing detection efficiency while decreasing detector thickness. Neutrons of interest create α particles that stop in a single CCD pixel. However, cosmic rays or energetic gammas and charged particles from other sources will penetrate several layers of CCD arrays, and activate multiple pixels in different layers. Then they could be mistaken for charged particles emitted from a boron slab. Coincidence measurements between adjacent arrays can be used to discriminate against energetic charged particles or gammas that penetrate several layers, in order to eliminate them from the measurement. If aligned cells 13 in two or more neighboring CCD arrays receive a charge nearly simultaneously, it can be concluded that this represents something other than a charged particle from a boron slab. This is because a particle from a slab will stop in the nearest CCD array, and will not go on to a next CCD. Therefore a technique for discrimination is available at all fluxes. In addition, Compton electrons produced by gammas lose energy in Si at a rate of only about 400 eV/μm, and so would deposit only a few KeV in the CCD depletion region, as opposed to α's which deposit all their energy. Thus, both coincidence between adjacent arrays, and a threshold for energy deposition, are available to discriminate against background gammas and charged particles. Less energetic background particles can be eliminated by encasing the entire detector in aluminum or in an optimized layered shielding material. About 1 to 2 gm/cm 2 of aluminum will stop all but the most energetic charged particles from entering the CCD, with no effect on the desired neutrons. Together with multiple layer anti-coincidence, false alarms could then occur only for those very few background particles of precisely enough energy to penetrate the Al, but which stop in the first CCD layer. The scheme for utilizing the detector should be evident from the foregoing description of its properties. Because no single slab of boron is thick enough to stop all thermal neutrons, but there is enough total thickness of boron to stop them all somewhere in the stack, it is likely that many or most of the slabs will stop some of them. Because the thickness of each individual slab is kept appropriately small, the charged particle produced in the neutron reaction with boron will be able to escape from that slab, and will be captured by the adjacent CCD array. It is a simple matter to accumulate the data relating to the total charge on each CCD array and add them together. This requires no more than the conventional controls for operating CCD arrays, and summation means, and this is within the scope of this invention. It is adequate for many uses. However, a suitably sophisticated system is needed to eliminate false data which could be generated by high energy particles that would not be stopped by the boron slabs, but still would provide a signal on the CCD arrays. The particles generated by a thermal neutron's reaction in the boron slab will go only to the adjacent CCD array. However, the more energetic particles will pass through several CCD arrays. This provides the basis for discrimination. The discriminator circuitry 21--(FIG. 2) will detect the fact of charges in two or more adjacent CCD arrays, in the same position on the arrays. Then these charges in the CCDs can be disregarded in the discriminator circuit, thereby eliminating this spurious data. The remaining data is unique to the thermal neutrons. The data received in either of these schemes may be displayed by a counter, or by a visual LCD or other display 22. Conventional controls such as off-on, rest, and the like, will also be provided. For example, any Si based CCD array of suitable thickness can be used together with a boron slab also of suitable thickness. These boron and CCD layers can be separately formed and then stacked, or instead can be formed by any suitable deposition process, or a combination of separate elements of one of them with a deposited layer by the other on it. Thus this invention is amenable to a wide range of materials and constructions, requiring only that the critical thicknesses be maintained as described above. The discrimator circuitry merely notes the coincidence of charges in adjacent CCDs at identical locations, and segregates that data from the remainder. The design of such circuitry is easily within the ability of a skilled designer of electronic circuitry. This invention is not to be limited by the embodiments shown in the drawings and described in the description, which are given by way of example and not of limitation, but only in accordance with the scope of the accompanying claims.
A detector for thermal neutrons comprising a stack of alternatingly arranged boron slabs and CCD arrays. The CCD arrays are receptive to energetic particles generated in the boron slabs by a thermal neutron, which energetic particles escape the boron slab in which they are generated and are captured by the next-adjacent CCD array, the CCD array being provided with circuit and power means to operate it and to read out the charges developed in the CCD arrays. The boron slabs are sufficiently thin that the energetic charged particles can escape, and the CCD arrays are sufficiently thick that the energetic particles will be trapped by them, and a charge will be developed therein which will be detected and measured.
6
TECHNICAL FIELD The present disclosure is directed to software application management in cloud computing environments. BACKGROUND Cloud infrastructure services, also known as Infrastructure as a Service (IaaS), deliver computer infrastructure—typically a platform virtualization environment—as a service, along with raw (block) storage and networking. Rather than purchasing servers, software, data-center space or network equipment, clients instead buy those resources as a fully outsourced service. A powerful abstraction supported by cloud computing is resource level abstraction by means of virtualizing the underlying physical resources. In this paradigm, users are relieved of the trouble of owning and managing physical computing resources. Instead, users can request computing resources from cloud providers using the provider's exposed APIs. One such example is Amazon's EC2, through which users can gain access to the desired computing resources. The users do not have any control over the physical resources, as the cloud provider provides a set of virtualized resources, such as servers/CPUs, storage and network bandwidth. In such a computing model, users are required to prepare the virtual images that will host the applications, known as virtual appliances. The benefit of such a model is that users are unaware of the underlying physical computing resources and do not need to manage the physical resources. The user's focus is on managing applications on top of these virtual resources. Due to the sharing of a common set of physical resources that are isolated by virtualization technologies, cloud providers can significantly lower the cost of computing resources. However managing applications in such a paradigm still poses a challenge for users. For example, in the advent of physical resource failures, users lack resiliency at the application level, and a hosted application or instance can be lost. BRIEF SUMMARY Exemplary embodiments of the invention as described herein generally include methods and systems for enabling users to manage their applications in the event of physical resource failures as well as some level of virtual resource level failures, and assumes little support from the cloud providers for application management. According to an aspect of the invention, there is provided a method of deploying a software application on the Internet cloud that is failure-tolerant, including identifying those aspects of a software application that need to be persisted in the event of failure, and those aspects of the application that do not need to be persisted, and deploying the application so that aspects that need to be persisted are deployed to persistent storage and aspects that do not need to be persisted are deployed to non-persistent virtual partitions, where when a virtual partition or an application component fails, an instance of the application is recreatable from those application aspects that were deployed to persistent storage. According to a further aspect of the invention, the method includes, when a virtual partition or an application component fails, redeploying the application, recovering persisted application aspects from persistent storage, and applying the recovered persistent aspects to the redeployed application, whereby the application state prior to the partition or component failure is recreated. According to a further aspect of the invention, application aspects that need to be persisted include data and stateful information that defines or is associated with an application state, and application aspects that do not need to be persisted include executable code and stateless information. According to a further aspect of the invention, identifying those aspects of a software application that need to be persisted and those aspects of the application that do not need to be persisted further comprises using application specific knowledge. According to a further aspect of the invention, the method includes saving to persisted storage any changes to application data and any changes to a state of the application. According to another aspect of the invention, there is provided a non-transitory program storage device readable by a computer, tangibly embodying a program of instructions executed by the computer to perforin the method steps for deploying a software application on the Internet cloud that is failure-tolerant. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS FIG. 1 depicts a cloud computing node according to an embodiment of the present invention. FIG. 2 depicts a cloud computing environment according to an embodiment of the present invention. FIG. 3 depicts abstraction model layers according to an embodiment of the present invention. FIG. 4 is a flowchart of a method of deploying a cloud application that allows for recovery in case of a failure, according to an embodiment of the invention. DETAILED DESCRIPTION It is understood in advance that although this disclosure includes a detailed description on cloud computing, implementation of the teachings recited herein are not limited to a cloud computing environment. Rather, embodiments of the present invention are capable of being implemented in conjunction with any other type of computing environment now known or later developed. Cloud computing is a model of service delivery for enabling convenient, on-demand network access to a shared pool of configurable computing resources (e.g. networks, network bandwidth, servers, processing, memory, storage, applications, virtual machines, and services) that can be rapidly provisioned and released with minimal management effort or interaction with a provider of the service. This cloud model may include at least five characteristics, at least three service models, and at least four deployment models. Characteristics are as Follows: On-demand self-service: a cloud consumer can unilaterally provision computing capabilities, such as server time and network storage, as needed automatically without requiring human interaction with the service's provider. Broad network access: capabilities are available over a network and accessed through standard mechanisms that promote use by heterogeneous thin or thick client platforms (e.g., mobile phones, laptops, and PDAs). Resource pooling: the provider's computing resources are pooled to serve multiple consumers using a multi-tenant model, with different physical and virtual resources dynamically assigned and reassigned according to demand. There is a sense of location independence in that the consumer generally has no control or knowledge over the exact location of the provided resources but may be able to specify location at a higher level of abstraction (e.g., country, state, or datacenter). Rapid elasticity: capabilities can be rapidly and elastically provisioned, in some cases automatically, to quickly scale out and rapidly released to quickly scale in. To the consumer, the capabilities available for provisioning often appear to be unlimited and can be purchased in any quantity at any time. Measured service: cloud systems automatically control and optimize resource use by leveraging a metering capability at some level of abstraction appropriate to the type of service (e.g., storage, processing, bandwidth, and active user accounts). Resource usage can be monitored, controlled, and reported providing transparency for both the provider and consumer of the utilized service. Service Models are as Follows: Software as a Service (SaaS): the capability provided to the consumer is to use the provider's applications running on a cloud infrastructure. The applications are accessible from various client devices through a thin client interface such as a web browser (e.g., web-based email). The consumer does not manage or control the underlying cloud infrastructure including network, servers, operating systems, storage, or even individual application capabilities, with the possible exception of limited user-specific application configuration settings. Platform as a Service (PaaS): the capability provided to the consumer is to deploy onto the cloud infrastructure consumer-created or acquired applications created using programming languages and tools supported by the provider. The consumer does not manage or control the underlying cloud infrastructure including networks, servers, operating systems, or storage, but has control over the deployed applications and possibly application hosting environment configurations. Infrastructure as a Service (IaaS): the capability provided to the consumer is to provision processing, storage, networks, and other fundamental computing resources where the consumer is able to deploy and run arbitrary software, which can include operating systems and applications. The consumer does not manage or control the underlying cloud infrastructure but has control over operating systems, storage, deployed applications, and possibly limited control of select networking components (e.g., host firewalls). Deployment Models are as Follows: Private cloud: the cloud infrastructure is operated solely for an organization. It may be managed by the organization or a third party and may exist on-premises or off-premises. Community cloud: the cloud infrastructure is shared by several organizations and supports a specific community that has shared concerns (e.g., mission, security requirements, policy, and compliance considerations). It may be managed by the organizations or a third party and may exist on-premises or off-premises. Public cloud: the cloud infrastructure is made available to the general public or a large industry group and is owned by an organization selling cloud services. Hybrid cloud: the cloud infrastructure is a composition of two or more clouds (private, community, or public) that remain unique entities but are bound together by standardized or proprietary technology that enables data and application portability (e.g., cloud bursting for load balancing between clouds). A cloud computing environment is service oriented with a focus on statelessness, low coupling, modularity, and semantic interoperability. At the heart of cloud computing is an infrastructure comprising a network of interconnected nodes. Referring now to FIG. 1 , a schematic of an example of a cloud computing node is shown. Cloud computing node 10 is only one example of a suitable cloud computing node and is not intended to suggest any limitation as to the scope of use or functionality of embodiments of the invention described herein. Regardless, cloud computing node 10 is capable of being implemented and/or performing any of the functionality set forth hereinabove. In cloud computing node 10 there is a computer system/server 12 , which is operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well-known computing systems, environments, and/or configurations that may be suitable for use with computer system/server 12 include, but are not limited to, personal computer systems, server computer systems, thin clients, thick clients, handheld or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputer systems, mainframe computer systems, and distributed cloud computing environments that include any of the above systems or devices, and the like. Computer system/server 12 may be described in the general context of computer system executable instructions, such as program modules, being executed by a computer system. Generally, program modules may include routines, programs, objects, components, logic, data structures, and so on that perform particular tasks or implement particular abstract data types. Computer system/server 12 may be practiced in distributed cloud computing environments where tasks are performed by remote processing devices that are linked through a communications network. In a distributed cloud computing environment, program modules may be located in both local and remote computer system storage media including memory storage devices. As shown in FIG. 1 , computer system/server 12 in cloud computing node 10 is shown in the form of a general-purpose computing device. The components of computer system/server 12 may include, but are not limited to, one or more processors or processing units 16 , a system memory 28 , and a bus 18 that couples various system components including system memory 28 to processor 16 . Bus 18 represents one or more of any of several types of bus structures, including a memory bus or memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISA) bus, Video Electronics Standards Association (VESA) local bus, and Peripheral Component Interconnects (PCI) bus. Computer system/server 12 typically includes a variety of computer system readable media. Such media may be any available media that is accessible by computer system/server 12 , and it includes both volatile and non-volatile media, removable and non-removable media. System memory 28 can include computer system readable media in the form of volatile memory, such as random access memory (RAM) 30 and/or cache memory 32 . Computer system/server 12 may further include other removable/non-removable, volatile/non-volatile computer system storage media. By way of example only, storage system 34 can be provided for reading from and writing to a non-removable, non-volatile magnetic media (not shown and typically called a “hard drive”). Although not shown, a magnetic disk drive for reading from and writing to a removable, non-volatile magnetic disk (e.g., a “floppy disk”), and an optical disk drive for reading from or writing to a removable, non-volatile optical disk such as a CD-ROM, DVD-ROM or other optical media can be provided. In such instances, each can be connected to bus 18 by one or more data media interfaces. As will be further depicted and described below, memory 28 may include at least one program product having a set (e.g., at least one) of program modules that are configured to carry out the functions of embodiments of the invention. Program/utility 40 , having a set (at least one) of program modules 42 , may be stored in memory 28 by way of example, and not limitation, as well as an operating system, one or more application programs, other program modules, and program data. Each of the operating system, one or more application programs, other program modules, and program data or some combination thereof, may include an implementation of a networking environment. Program modules 42 generally carry out the functions and/or methodologies of embodiments of the invention as described herein. Computer system/server 12 may also communicate with one or more external devices 14 such as a keyboard, a pointing device, a display 24 , etc.; one or more devices that enable a user to interact with computer system/server 12 ; and/or any devices (e.g., network card, modem, etc.) that enable computer system/server 12 to communicate with one or more other computing devices. Such communication can occur via Input/Output (I/O) interfaces 22 . Still yet, computer system/server 12 can communicate with one or more networks such as a local area network (LAN), a general wide area network (WAN), and/or a public network (e.g., the Internet) via network adapter 20 . As depicted, network adapter 20 communicates with the other components of computer system/server 12 via bus 18 . It should be understood that although not shown, other hardware and/or software components could be used in conjunction with computer system/server 12 . Examples, include, but are not limited to: microcode, device drivers, redundant processing units, external disk drive arrays, RAID systems, tape drives, and data archival storage systems, etc. Referring now to FIG. 2 , illustrative cloud computing environment 50 is depicted. As shown, cloud computing environment 50 comprises one or more cloud computing nodes 10 with which local computing devices used by cloud consumers, such as, for example, personal digital assistant (PDA) or cellular telephone 54 A, desktop computer 54 B, laptop computer 54 C, and/or automobile computer system 54 N may communicate. Nodes 10 may communicate with one another. They may be grouped (not shown) physically or virtually, in one or more networks, such as Private, Community, Public, or Hybrid clouds as described hereinabove, or a combination thereof. This allows cloud computing environment 50 to offer infrastructure, platforms and/or software as services for which a cloud consumer does not need to maintain resources on a local computing device. It is understood that the types of computing devices 54 A-N shown in FIG. 2 are intended to be illustrative only and that computing nodes 10 and cloud computing environment 50 can communicate with any type of computerized device over any type of network and/or network addressable connection (e.g., using a web browser). Referring now to FIG. 3 , a set of functional abstraction layers provided by cloud computing environment 50 ( FIG. 2 ) is shown. It should be understood in advance that the components, layers, and functions shown in FIG. 3 are intended to be illustrative only and embodiments of the invention are not limited thereto. As depicted, the following layers and corresponding functions are provided: Hardware and software layer 60 includes hardware and software components. Examples of hardware components include mainframes, in one example IBM® zSeries® systems; RISC (Reduced Instruction Set Computer) architecture based servers, in one example IBM pSeries® systems; IBM xSeries® systems; IBM BladeCenter® systems; storage devices; networks and networking components. Examples of software components include network application server software, in one example IBM WebSphere® application server software; and database software, in one example IBM DB2® database software. (IBM, zSeries, pSeries, xSeries, BladeCenter, WebSphere, and DB2 are trademarks of International Business Machines Corporation registered in many jurisdictions worldwide). Virtualization layer 62 provides an abstraction layer from which the following examples of virtual entities may be provided: virtual servers; virtual storage; virtual networks, including virtual private networks; virtual applications and operating systems; and virtual clients. In one example, management layer 64 may provide the functions described below. Resource provisioning provides dynamic procurement of computing resources and other resources that are utilized to perform tasks within the cloud computing environment. Metering and Pricing provide cost tracking as resources are utilized within the cloud computing environment, and billing or invoicing for consumption of these resources. In one example, these resources may comprise application software licenses. Security provides identity verification for cloud consumers and tasks, as well as protection for data and other resources. User portal provides access to the cloud computing environment for consumers and system administrators. Service level management provides cloud computing resource allocation and management such that required service levels are met. Service Level Agreement (SLA) planning and fulfillment provide pre-arrangement for, and procurement of, cloud computing resources for which a future requirement is anticipated in accordance with an SLA. Workloads layer 66 provides examples of functionality for which the cloud computing environment may be utilized. Examples of workloads and functions which may be provided from this layer include: mapping and navigation; software development and lifecycle management; virtual classroom education delivery; data analytics processing; and transaction processing. Embodiments of the invention provides users with mechanisms for deploying their application in such a way that important state information, such as configurations and data, are persisted in appropriate storage for possible retrieval in the future. Embodiments of the invention provides users with mechanisms to re-engineer and construct the deployment process such that a virtual machine (VM) instance can be restored after a failure with very minimal support from a cloud provider. Application components can be mapped in the deployment plan onto cloud resource elements, to account for availability/persistent nature of cloud elements and application requirements. A method according to an embodiment of the invention includes 3 steps: (1) identifying cloud components of an application in terms of service quality, that is, those that are persistent and those that are not; (2) identifying those components of an application that need to be persisted, and those that do not, and splitting the application accordingly; and (3) mapping these application components into cloud elements and linking these post deployment. The application is deployed so that either the persistent information is mounted to storage partitions that are hosted on persisted storage, or only image binaries that are part of the generic virtual appliance images are kept in the virtual machines (VMs). If the VM goes down either due to virtual machine or underlying physical resource problems, the user can recover the application with very little support from the cloud. The user only requires support to recover the persisted information and apply these changes to the original virtual appliance to reconfigure the application with the correct configuration state and persisted data. Embodiments of the invention can structure the storage partition management appropriately, for example by using application models that are built from a knowledge base, so that it knows which partitions are configuration related, and what data needs to be persisted. Embodiments of the invention can transparently map these at the application provisioning phase (see below) and persist this information, and can enable the service provider to recover this persisted information. When an application needs to be restored, it recovers this required information and modifies the appropriate information to synchronize with the recovered information. According to an embodiment of the invention, two primitives allow users to manage their applications in the event of underlying cloud resource failures, as described below. (1) Application Provisioning Phase: A cloud deployment pattern engine intercepts a user's request for application deployment and instruments the deployment in such a way that persistent storage is used for any stateful information and for directories that keep track of configuration level information as well as any data that is required to be persisted for future use. The cloud deployment pattern engine maps stateful components into cloud elements that are persisted, and stateless components into cheaper, non-persistent cloud elements. Typically, stateful components include data, whereas the application executable code would be considered stateless. For example, for an Apache HTTP server, the binaries that are bundled as a virtual appliance can always be downloaded from the cloud, or user based images for the applications. Only a few directories that keep track of configurations, such as in/conf, and any user created data files, such as contents in /httpdocs, are mounted to persistent storage. Thus any changes made by users to these directories are always kept in recoverable storage. There are generally three type of storage, determined by cost and functionality: (1) local storage on the VM itself, which is not persistent; (2) block level storage, such as Amazon EBS; and (3) object based storage, such as Amazon S3 and Google Storage. Metadata may be sued to determine in which type of storage data should be stored. The metadata will be provided as an API to the Cloud deployment pattern engine by each application stack. Alternatively, the metadata could be based on best practices, and a database could be created for each application to keep such information. For example, if the application is DB2, DB2 experts will list the set of files that need to be persisted, and this set of files will maintain the configuration state that will be used to recreate the state of the application for recovery later on. Knowledge about which directories need to be persisted may be derived from a knowledgebase or with some lower level discovery mechanism. The cloud deployment pattern engine can transparently work with cloud instance creation APIs to facilitate this pattern in the provisioning phase. After a user has customized an application or made changes to an application state, a snapshot of the application state can be created to create a virtual backup copy of the application. Many cloud providers provide APIs to create such snapshots, which can be customized to automatically create a snapshot at certain frequencies. The golden image can be created by the cloud provider as a set of base mages that a customer uses to start an installation. (2) Application Redeployment Phase: In the event of any underlying VM or cloud resource failure, a cloud redeployment pattern engine can recover the persisted information and binary images from an image repository and apply these changes to the applications if the application needs to be reinstalled. The cloud redeployment pattern engine remaps persisted elements onto newly created deployments, and stateless components are redeployed using golden images. The redeployment pattern engine uses the golden image from the application catalog. For example, if DB2 has to restored, it takes the DB2 golden images. From the metadata about which files keep the state of DB2, the redeployment pattern engine learns which links to establish to point to those files/directories. The redeployment pattern engine either rewrites these files in the golden image or creates links to these saved files to recreate the state. It obtains the binary images from the image repository and persisted information from cloud persistent storage. Using both of this information, it patches the instantiated image with the changes to bring the application back into the correct state. According to an embodiment of the invention, in an instance creation phase, the cloud deployment pattern engine intercepts a users request to create an image instance. The cloud deployment pattern engine uses application specific knowledge to determine which information needs to be persisted and, at the create instance phase, uses this knowledge for application deployment. Thus, any changes to the state and data are saved to storage that is persisted beyond the instance life cycle. For example, a user chooses a service and specifies deployment parameters. A service mapper maps the user requirements into an image specific deployment plan. A cloud deployment pattern engine according to an embodiment of the invention uses best practices template or business resiliency specific solutions to annotate the deployment plan into two specific categories for each elements: (1) stateful requirements; and (2) stateless requirements. A trigger for recreating the application occurs if, for example, the VM stops responding, or a physical resource has failed. In both cases, the hosted application will fail. According to an embodiment of the invention, in an instance recreation phase, the cloud redeploy pattern engine can recreate an instance of the application and restore the instance to its last known state. The cloud redeploy pattern engine can obtain the appropriate binary images from the user or a cloud repository, and can obtain persisted state information by using the pattern knowledge kept in the knowledgebase at the deployment phase. The cloud redeploy pattern engine then recreates the instance and applies changes using the recovered information. FIG. 4 is a flowchart of a method according to an aspect of the invention for deploying a software application on the Internet cloud that is failure-tolerant. Referring now to the figure, a method according to an aspect of the invention begins at step 41 by identifying those aspects of the application that need to be persisted in the event of failure, and those aspects of the application that do not need to be persisted. Application specific knowledge can be used to help identify those aspects of a software application that need and do not need to be persisted. Application aspects that need to be persisted include data and stateful information that defines or is associated with an application state, and aspects that do not need to be persisted include executable code and stateless information. At step 42 , the application is deployed so that aspects that need to be persisted are deployed to persistent storage and aspects that do not need to be persisted are deployed to non-persistent virtual partitions. While the application is running, any subsequent changes to the application data or to a state of the application are saved to persisted storage at step 43 . If, however, at step 44 , a virtual partition or an application component fails, an instance of the application is recreatable from those application aspects that were deployed to persistent storage. In particular, at step 45 , the application is redeployed, and persisted application aspects are recovered from persistent storage and applied to the redeployed application to recreate the application state prior to the failure. While exemplary embodiments of the invention has been described in detail with reference to the attached drawing figures, those skilled in the art will appreciate that various modifications and substitutions can be made thereto without departing from the spirit and scope of the embodiments of the invention as set forth in the appended claims.
A semiconductor device includes a first layer, first and second active areas disposed on the first layer; a trench disposed between the first and second active areas, an insulating oxide that fills the trench to a level below a surface of the first and second active layers, and a nitride cap disposed on top of the insulating oxide so that the first and second active areas can be cleaned without damaging the insulating oxide. A top surface of the nitride cap in regions adjacent to the first and second active areas in aligned with a top surface of the first and second active areas, a top surface of the nitride cap in a center region of the nitride cap is stepped below the top surface of the adjacent regions, and a void is formed between the top surface regions adjacent to the first and second active areas.
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CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority based on U.S. provisional application 61/043,817 which was filed Apr. 10, 2008, and also U.S. Ser. No. 12/416,179 filed Apr. 1, 2009. [0002] This application also claims priority on U.S. application Ser. No. 12/184,740 filed on Aug. 1, 2008, and its parent U.S. application Ser. No. 11/268,151 filed on Nov. 7, 2005, both of which are incorporated herein by reference as if fully set forth herein. STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT [0003] Not applicable. BACKGROUND OF THE INVENTION [0004] The present invention relates to flush valves that control the flow of water from toilet tanks to toilet bowls. More particularly, the invention relates to a tank valve seat mountable to a toilet tank and preferably used with canister type flush valves. [0005] Many systems for controlling the flow of toilet tank water to a toilet bowl are known. Such systems have a water inlet valve connected to the tank that is typically controlled by a float that reacts to the tank water level. Depressing a trip lever or other actuator moves a flush valve at the tank outlet so that water can empty from the tank into the bowl. As the tank water drains, an inlet valve float drops with the water level in the tank, thereby triggering inlet water flow to refill the tank. After sufficient tank water leaves the tank, the flush valve closes so that the water level in the tank can be re-established. As the tank refills after the outlet valve has closed, the supply valve float rises with the water and eventually closes the supply valve to shut off the water supply. [0006] A variety of flush valves have been devised for controlling the flow of water from the tank to the bowl. One of the most common is the flapper type flush valve. Flapper flush valves have a pivotal yoke that supports a large diameter stopper that seals off the tank outlet until the trip lever is actuated to start a flush cycle. The large stopper is filled with air that slows the reseating of the stopper until sufficient water has been drained from the tank. On occasion, some such valves have difficulty in completely closing off outlet flow if the flapper doesn't drop onto the valve seat exactly right. [0007] Another type of flush valve has a dedicated float that moves straight vertically upwards once tripped, and then straight vertically downward. See e.g. U.S. Pat. Nos. 5,329,647, 5,896,593, 6,715,162, and 6,728,976. [0008] A particularly preferred type of flush valve that works in this manner is the canister flush valve shown in U.S. patent application publication 2007/0101485, which is hereby incorporated by reference as if fully set forth herein. However, this type of canister design, when used with its shown valve seat, presents a number of design constraints. [0009] For example, to achieve sufficient initial flow one may have to increase the diameter of the entry to the bowl's rear extension to a point where non-standard fittings are required, and/or aesthetics are affected. Moreover, the flow characteristics may be such as to limit certain water usage efficiencies that must be compensated for otherwise. [0010] One complicating factor is that in order to insure vertical movement of the valve body, a guide is positioned on the valve seat. As this is typically at the center of the flow passage through the seat, the guide itself can impede flow and complicate design revisions. While U.S. Pat. No. 5,926,861 proposes to have the guide for the canister be at the periphery of the seat, it requires a relatively complex and expensive structure to implement that proposal. [0011] In light of the above, improvements are needed to address these concerns. SUMMARY OF THE INVENTION [0012] The present invention covers in one aspect a flush valve for controlling a flow of water out through a hole in a wall of a toilet tank. The flush valve has a mounting having a lower end suitable for facilitating installation of the mounting adjacent the hole, an upper end in a form of a valve seat, and a through passage extending down from the valve seat. It also has a guide portion mounted in the through passage and extending upward there from. [0013] There is also a valve body positionable over the valve seat so as to be suitable to inhibit water flow through the mounting when in a first position where the valve body is positioned on the valve seat, and so as to be suitable to permit water flow through the mounting when the valve body is in a second position where the valve body is not positioned on the valve seat. In accordance with the present invention the through passage tapers below the valve seat. [0014] In preferred forms the through passage arcuately narrows below the valve seat from a diameter above 2.9 inches to a diameter below 2.3 inches, more preferably below 2.1 inches, the valve body is a canister type valve body, the guide portion has a lower leg structure that tapers arcuately below the valve seat, and the mounting has external threads proximate a lower end of the mounting so as to facilitate installation of the mounting through the tank hole. Alternatively, when a one-piece style toilet is involved with a blind attachment hole, instead of threading the lower end of the structure one can use a bayonet style attachment system like that of U.S. Pat. No. 4,433,446. [0015] It will be appreciated that the enlarged valve seat and correspondingly large canister valve produces a large discharge flow rate of water to enter as soon as the canister valve is lifted off the valve seat. The tapering of the passageway below the valve seat (and the corresponding tapering of the guide portion) then permit the flow to be smoothly transitioned to the desired size with no impedance to the developed flow rate. [0016] In another aspect the invention provides a mounting useful as part of such a flush valve. That mounting may have a body in the form of a sleeve and have a lower end suitable for facilitating installation of the body adjacent a tank wall outlet hole. The mounting also has an upper end in a form of a valve seat, a through passage extending down from the valve seat, and a guide post mounted in the through passage and extending upward there from. The through passage tapers below the valve seat. [0017] It should be noted that the guide post can be centered along the center line of the canister valve body for optimal guiding. This is also a cost effective way of achieving the guiding. However, adequate flow can occur past the guide portion, even in connection with low flush toilets. [0018] In another aspect the invention provides a toilet (with tank and bowl), where the above flush valve controls outflow from the tank to the bowl. [0019] Hence, the present invention improves the performance of conventional, high performance, canister valves so as to permit an uncompromised discharge flow rate of water to quickly pass into the toilet once flushing has started. This is achieved at relatively low cost, and in a manner that does not require the bowl rear extension to be widened to accommodate the greater flow. [0020] These and other advantages of the invention will be apparent from the detailed description and drawings. What follows are one or more preferred embodiments of the present invention. To assess the full scope of the invention the claims should be looked to as the preferred embodiment(s) are not intended as the only embodiment(s) within the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS [0021] FIG. 1 is a sectional view depicting a flush valve of the present invention installed in a toilet tank of the present invention; [0022] FIG. 2 is a top plan view of the FIG. 1 , with the tank cover removed; [0023] FIG. 3 is a perspective view of the FIG. 1 flush valve; [0024] FIG. 4 is an exploded perspective view of the FIG. 2 flush valve; [0025] FIG. 5 is a view similar to FIG. 4 , but showing the parts from a different angle; [0026] FIG. 6 is a sectional view taken along line 6 - 6 of FIG. 3 ; [0027] FIG. 7 is a sectional view taken along line 7 - 7 of FIG. 3 ; [0028] FIG. 8 is an enlarged detail view per arc 8 - 8 of FIG. 6 ; [0029] FIG. 9 is an enlarged top perspective view of a preferred mounting of the present invention; [0030] FIG. 10 is a bottom perspective view of the FIG. 9 mounting; and [0031] FIG. 11 is a view similar to FIG. 6 , but showing the canister valve body raised to a second position off the valve seat. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0032] Referring first to FIGS. 1 and 2 , a toilet 10 is shown that includes a water tank 12 and a bowl 14 (partially shown in hidden lines). The tank 12 may be coupled to the bowl 14 using a bracket like that of U.S. Pat. No. 6,728,976. [0033] The tank 12 includes a cover 16 and a generally horizontal bottom wall 18 with an outlet opening 20 that leads to a channel in an upper rim (not shown) of the bowl 14 . Mounted inside the tank is the typical water supply pipe 22 with a float 24 operated supply valve 26 for controlling the flow of supply water 28 into the tank 12 . In this regard, when the float drops (as water has exited the tank), water is supplied to the tank. Once the float follows the water back up far enough, the supply water automatically turns off. [0034] A flush valve assembly 30 in accordance with the present invention is mounted inside the tank 12 over the outlet opening 20 to control the flow of water 28 out from the tank 12 to the bowl 14 during a flush cycle. A trip lever assembly 31 is coupled to the tank 12 and to a portion of the flush valve assembly 30 and can be triggered to initiate a flush cycle. [0035] With additional reference to FIGS. 3-5 , the flush valve assembly 30 is mounted vertically upright in the tank 12 proximate the bottom wall 18 . The flush valve assembly 30 primarily includes a mounting 32 and a valve body 34 incorporating a seal 36 that moves relative to the mounting 32 generally along a central axis 38 (shown in FIGS. 2 and 3 ). The mounting 32 and the valve body 34 are preferably constructed of a non-corrosive, chemical resistant material, such as a suitable plastic. The seal 36 can be made of a flexible material, for example a suitable elastomer, such as vinyl, EPDM rubber, or silicon, which has particularly good chemical/corrosion resistance properties. However, one skilled in the art will appreciate the variety of materials suitable for the mounting 32 , valve body 34 , and seal 36 . [0036] The mounting 32 is coupled to the tank 12 by a retaining nut 39 that threads onto exterior threads 40 formed proximate the lower portion 42 of the mounting 32 that extends through the tank outlet opening 20 . An annular flange 44 extends radially from the mounting 32 to sandwich a gasket 46 between the bottom wall 18 of the tank 12 and the flange 44 (best shown in FIG. 1 ). This gasket 46 prevents water 28 from leaking from the tank 12 and, for instance, onto the floor of a bathroom. [0037] In one alternate example configuration not shown, the lower portion 42 of the mounting 32 can have three prongs that extend through a trilobular opening and engage the tank 12 . This connection is similar to that disclosed in U.S. Pat. No. 4,433,446, which is assigned to the assignee of the present invention, and the disclosure of which, particularly FIGS. 2-6 and the related description, is hereby incorporated by reference. [0038] With additional reference to FIGS. 6-11 , the mounting 32 defines a passageway 48 that extends between a valve seat 50 at one end and a valve outlet 52 at the opposite end. The passageway 48 defines a substantially arcuate surface 54 that tapers down from the valve seat 50 toward the valve outlet 52 , as best shown in FIG. 6 . The arcuate surface 54 may be smooth to minimize impediment to the flow of water 28 . Additionally, the arcuate surface 54 is preferably contoured to mimic the natural flow of water 28 so as to maximize the flow rate of the water 28 from the tank 12 to the bowl 14 . The passageway 48 includes a linear portion 56 proximate the valve outlet 52 ; however, the passageway 48 may be entirely arcuate from the valve seat 50 to the valve outlet 52 . [0039] In the preferred example embodiment, the valve seat 50 and the valve outlet 52 are preferably concentric with respect to a central axis 38 . The valve seat 50 is substantially circular and has a valve seat diameter 58 that is greater than a valve outlet diameter 60 (shown in FIGS. 9 and 10 ). The valve outlet 52 is also substantially circular. [0040] In the example embodiment, the valve seat diameter 58 is approximately three inches to allow for a sufficient amount of water 28 to flow both during the initial inrush of a flush cycle and during the balance of the flush cycle. The passageway 48 reduces the larger valve seat diameter 58 to a valve outlet diameter 60 of approximately two inches proximate the valve outlet 52 . As a result, the passageway 48 funnels or directs the water 28 toward the bowl 14 , providing sufficient bowl 14 cleaning and waste removal water 28 during a flush cycle, and to permit coupling the mounting 32 to more traditional components and fixtures. [0041] The passageway 48 may take on a variety of arcuate surface configurations of reducing cross section, with each having a goal of efficiently transferring water 28 from the tank 12 to the bowl 14 during a flush cycle. The tapered passageway 48 has the added benefit of making the mounting 32 compatible with standard bowls and other coupling components, while allowing the enhanced flow of water 28 . [0042] The mounting 32 includes a series of supports 62 in the form of arcuately tapered legs that extend inward from the passageway 48 and converge proximate the central axis 38 where they define an opening 64 . The supports 62 taper below the valve seat 50 toward the valve outlet 52 to maximize the flow of water 28 through the passageway 48 . The opening 64 is configured to receive a guide portion 66 in the form of a post. The guide portion 66 has a pair of legs 68 formed proximate a lower end 70 that selectively lock into the opening 64 to prevent axial movement of the guide portion 66 . [0043] The guide portion 66 also includes upwardly extending tapered gussets 72 that terminate in a hollow upper end 74 that is configured to receive a refill nozzle 76 and stop washer 78 that captures the valve body 34 to the guide portion 66 . During a flush cycle, the refill nozzle 76 receives water 28 from the supply valve 26 via tube 80 . The refill nozzle 76 allows water 28 to fill a portion of the valve body 34 and tank 12 during a flush cycle to influence the duration of the flush cycle and to restore the bowl water to an initial level. [0044] The substantially cup-shaped valve body 34 is a type of float that is open to the ambient at a top 35 and includes an exterior wall 85 and an interior tube 86 that generally rides along the guide portion 66 during a flush cycle. The interior tube 86 is substantially conical and tapers toward an upper rim 88 of the tube 86 . The conical configuration of the interior tube 86 acts to center the valve body 34 with respect to the mounting 32 as the valve body 34 sinks from the raised position to the lowered position. Should water 28 breach the upper rim 82 of the valve body 34 , the water 28 begins to fill a circular pocket 84 formed between the interior tube 86 and the exterior wall 85 . The water 28 drains through openings 73 first and then climbs to upper rim 88 of the interior tube 86 if the incoming overflow rate is high enough. Note also gussets 72 . [0045] The trip lever assembly 31 includes a chain 98 that is hooked between hole 100 formed in a side tab 102 of the valve body 34 and the trip arm 104 , as a result, actuating the trip lever assembly 31 moves the valve body 34 from the lowered position (shown in FIG. 6 ) toward the raised position (shown in FIG. 11 ). [0046] With specific reference to FIGS. 6-8 , when the valve body 34 is in the lowered position, the seal 36 prevents water 28 from leaking from the tank 12 to the bowl 14 proximate a perimeter 96 of the mounting 32 . The typically disk-shaped seal 36 is secured in an annular groove 90 formed proximate the lower end 92 of the valve body 34 . In the preferred example embodiment, the seal 36 at least partially engages a ridge 94 that extends upward from the valve seat 50 proximate the perimeter 96 of the valve seat 50 (shown best in FIG. 8 ) to help establish a watertight seal between the seal 36 and the valve seat 50 . Furthermore, an annular seal-backing flange 106 is spaced apart from the seal 36 and enhances the operation and sealing of the seal 36 . Additionally, a series of slots 108 are formed in the seal-backing flange 106 to enhance the operation of the valve body 34 during a flush cycle. One skilled in the art will appreciate the variety of configurations available to retain the seal 36 to the valve body 34 . [0047] The bleed openings 73 , seal-backing flange 106 , slots 108 , and other additional structures are discussed in U.S. patent application number 2007/0101485 that is assigned to the assignee of the present invention, which is hereby incorporated by reference as if fully set forth herein. [0048] Prior to a flush cycle the flush valve is in the rest position shown in FIGS. 1 , 3 , 6 , and 7 , with the valve body 34 and seal 36 seated on the valve seat 50 and a “full” tank 12 of water 28 available. Actuating the trip lever assembly 31 pulls the valve body 34 upwardly a sufficient distance to cause the seal 36 to unseat from the valve seat 50 . When the seal 36 is initially unseated from the valve seat 50 , the flared valve seat 50 portion of the passageway 48 allows the water 28 to flow into the bowl 14 with an initial inrush equivalent to a valve of uniform diameter of valve seat 50 . [0049] Through the buoyancy of the valve body 34 , the valve body 34 is moved further toward the raised position shown in FIG. 11 . The water 28 in the tank 12 continues to flow through the mounting 32 along the arcuate surface 54 of the passageway 48 that mimics the natural flow of water 28 toward the bowl 14 . Additionally, the tapered supports 62 minimize water 28 flow resistance in the passageway 48 . Water 28 and waste in the bowl 14 are evacuated to plumbing waste lines in the usual manner through a trap (not shown). The valve body 34 travels down the guide portion 66 until the seal 36 again seats in the valve seat 50 in conjunction with an engineered bleed rate controlled by openings 73 . The flush cycle completes after the tank 12 is refilled with water 28 sufficient to trip the supply valve 26 . [0050] It should be appreciated that preferred embodiments of the invention have been described above. However, many modifications and variations to the preferred embodiments will be apparent to those skilled in the art, which will be within the spirit and scope of the invention. Therefore, the invention should not be limited to the described embodiments. To ascertain the full scope of the invention, the following claims should be referenced. INDUSTRIAL APPLICABILITY [0051] The present invention provides improved valves for use in controlling outflow of water from a toilet tank to a toilet bowl, and toilets which incorporate these valves.
A canister flush valve is disclosed with a valve seat modified to accommodate a greater initial surge of flow, without distorting flushing performance. There is a mounting at the bottom of a toilet tank that links to an outlet hole from the tank and forms a valve seat. A passageway through the mounting tapers in an arcuate manner below the valve seat. There is also a guide support structure in the passageway, preferably centered. The guide support structure also has a tapered leg.
4
CROSS-REFERENCE TO RELATED APPLICATIONS The benefit of prior provisional application Ser. No. 60/055,189, filed on Aug. 11, 1997, is hereby claimed. FIELD OF THE INVENTION The invention relates to novel 5,11-dihydro-6H-dipyrido 3,2-b:2',3'-e!azepine-6-ones and pharmaceutically acceptable salts thereof, methods for preparing these compounds, the use of these compounds either alone or in combination with other anti-virals, immunomodulators, antibiotics, anti-infectives, or vaccines in the prevention or treatment of HIV infection, and to pharmaceutical compositions containing these compounds. BACKGROUND OF THE INVENTION The human disease, Acquired Immune Deficiency Syndrome (AIDS), is caused by the Human Immunodeficiency Virus (HIV), particularly the strain known as HIV-1. Like other viruses, HIV-1 cannot replicate without commandeering the biosynthetic apparatus of the host cell it infects. It causes this apparatus to produce the structural proteins which make up the viral progeny. These proteins are coded for by the genetic material contained within the infecting virus particle, or virion. Being a retrovirus, however, the genetic material of HIV is RNA, not DNA as in the host cell's genome. Accordingly, the viral RNA must first be converted into DNA, and then integrated into the host cell's genome, in order for the host cell to produce the required viral proteins. The conversion of the RNA to DNA is accomplished through the use of the enzyme reverse transcriptase (RT), which is included within the infecting virion along with the RNA. Reverse transcriptase has three known enzymatic functions; it acts as an RNA-dependent DNA polymerase, as a ribonuclease, and as a DNA-dependent DNA polymerase. Acting first as an RNA-dependent DNA polymerase, RT makes a single-stranded DNA copy of the viral RNA. Acting as a ribonuclease, RT frees the DNA just produced from the original viral RNA and destroys the original RNA. Finally, acting as a DNA-dependent DNA polymerase, RT makes a second, complementary DNA strand, using the first DNA strand as a template. The two strands form double-stranded DNA, which is integrated into the host cell's genome by another enzyme called integrase. Compounds which inhibit the enzymatic functions of HIV-1 reverse transcriptase will inhibit replication of HIV-1 in infected cells. A number of compounds that inhibit the enzymatic functions of HIV-1 reverse transcriptase are known. One class of known HIV-1 RT inhibitors is the nucleoside analogs. This class includes 3'-azido-3'-deoxythymidine (AZT), 2',3'-dideoxyinosine (ddI), and 2',3'-dideoxy-cytidine (ddC). Another class is the non-nucleoside analogs. This class includes, inter alia, nevirapine, which is 11-cyclopropyl-5,11-dihydro-4-methyl-6H-dipyrido 3,2-b:2',3'-e! 1,4!-diazepin-6-one. Nevirapine and other paricularly relevant compounds of the non-nucleoside class are described in U.S. Pat. No. 5,366,972; by Hargrave et al.,"Novel Non-Nucleoside Inhibitors of HIV-1 Reverse Transcriptase. 1. Tricyclic Pyridobenzo-and Dipyridodiazepinones", J. Med. Chem., 34, 2231 (1991); and by Proudfoot et al., "Novel Non-Nucleoside Inhibitors of HIV-1 Reverse Transcriptase. 4.2-Substituted Dipyridodiazepinones are Potent Inhibitors of both Wild Type and Cysteine-181 HIV-1 Reverse Transcriptase Enzymes". J. Med. Chem., 38, 4830-4838 (1995). OBJECT OF THE INVENTION As with any anti-viral therapy, use of RT inhibitors in the treatment of HIV-1 infection tends to produce virus which is less sensitive to the given drug. Resistance (reduced sensitivity) to these drugs is the result of mutations which occur in the reverse transcriptase segment of the pol gene. The object of the present invention is to provide improved, non-nucleoside inhibitors of HIV-1 RT which are more potent against mutant strains of HIV-1 than the known compounds of this class. The compounds of the present invention satisfy this object in that they are highly potent against not only the wild-type (non-mutated) virus RT enzyme, but are also effective against the Y181C mutant in which the tyrosine (Y) at codon 181 has been mutated to a cysteine (C) residue! which has been the most commonly observed mutant in clinical studies following therapy with many non-nucleoside reverse transcriptase inhibitors. SUMMARY OF THE INVENTION A first aspect of the invention comprises novel 5,11-dihydro-6H-dipyrido 3,2-b:2',3'-e!azepine-6-ones. These possess inhibitory activity against both wild-type and mutant HIV-1 RT. A second aspect of the invention comprises methods for making these novel compounds. A third aspect of the invention is a method for inhibiting replication of HIV-1 in a human host infected by HIV-1. A fourth aspect of the invention is a method for preventing or treating HIV-1 infection which comprises administering, to a human being exposed to or infected by HIV-1, a prophylactically or therapeutically effective amount of one of the above-mentioned novel compounds, either alone or in combination with other anti-viral agents, immunomodulators, antibiotics, anti-infectives, or vaccines. A final aspect of the invention comprises pharmaceutical compositions suitable for the prevention or treatment of HIV-1 infection comprising the above-mentioned compounds. DESCRIPTION OF THE INVENTION In one of its composition of matter aspects, the invention comprises 5,11-dihydro-6H-dipyrido 3,2-b:2',3'-e!azepine-6-ones of formula 1 ##STR2## wherein; X is an oxygen atom or nothing; R 1 is hydrogen, alkyl of 1 to 4 carbon atoms, fluoroalkyl of 1 to 4 carbon atoms and 1 to 3 fluorine atoms, cycloalkyl of 3 to 6 carbon atoms, alkylthio of 1 to 2 carbon atoms, alkyloxy of 1 to 2 carbon atoms, oxetanyl, thietanyl, tetrahydrofuranyl, tetrahydrothienyl, tetrahydropyranyl, tetrahydrothiopyranyl, alkenylmethyl or alkynylmethyl of 3 to 4 carbon atoms, alkyloxyalkyl or alkylthioalkyl of 2 to 3 carbon atoms, alkanoyl or alkyl(thiocarbonyl) of 2 to 5 carbon atoms, or cyanoalkyl of 2 to 3 carbon atoms; R 2 is hydrogen, methyl or ethyl; R 3 is a hydrogen atom, alkyl of 1 to 6 carbon atoms, cycloalkyl of 3 to 6 carbon atoms, alkenyl or alkynyl of 2 to 6 carbon atoms, trihalomethyl, hydroxyalkyl of 1 to 6 carbon atoms, alkyloxy or alkylthio of 2 to 6 carbon atoms, alkyloxyalkyl or alkylthioalkyl of 2 to 6 carbon atoms, pyrrolidinyl, pyrrolinyl, piperidinyl, mono-or di-alkylamino wherein each alkyl moiety contains 1 to 3 carbon atoms, halogen, cyano, nitro, or carboxyl, aryl (wherein aryl is phenyl, pyridinyl, thienyl, furanyl, pyrrolyl, imidazolyl, pyrazolyl, oxazolyl, isoxazolyl, thiazolyl or isothiazolyl) which is either unsubstituted or substituted by hydroxyl, amino, halogen, alkyl or alkyloxy of 1 to 3 carbon atoms. A subgeneric aspect of the invention comprises compounds of formula 1, wherein: X is nothing; R 1 is hydrogen, alkyl of 1 to 3 carbon atoms, cycloalkyl of 3 to 4 carbon atoms, alkylthio of 1 to 2 carbon atoms; R 2 is hydrogen, methyl or ethyl; R 3 is a hydrogen atom, methyl, trihalomethyl, alkyloxy or alkylthio of 1 to 2 carbon atoms, pyrrolidinyl, pyrrolinyl, piperidinyl, di-alkylamino wherein each alkyl moiety contains 1 to 2 carbon atoms, halogen, cyano, aryl (wherein aryl is phenyl, pyridinyl, thienyl, furanyl, pyrrolyl, imidazolyl, pyrazolyl, oxazolyl, isoxazolyl, thiazolyl or isothiazolyl) which is either unsubstituted or substituted by hydroxyl, amino, halogen, alkyl or alkyloxy of 1 to 3 carbon atoms. A particular subgeneric aspect of the invention comprises compounds of formula 1, wherein: X is nothing; R 1 is ethyl, cyclopropyl, or methylthio; R 2 is hydrogen; R 3 is hydrogen, chloro, methoxy or 4-pyrazolyl. Preferred compounds of formula 1 are: 5-methyl-11-ethyl-2-(4-pyrazolyl)-5,11-dihydro-6H-dipyrido 3,2-b:2',3'-e!azepine; 5-methyl-11-ethyl-2-methoxy-5,11-dihydro-6H-dipyrido 3,2b:2',3'-e!azepine. Synthesis Of Compounds Of Formula 1 And Their Salts The compounds of Formula 1 and their salts can be prepared by known methods, or obvious modifications thereof, in accordance with the general synthetic scheme shown below. ##STR3## Method A Compounds of formula 1 ##STR4## wherein R 1 through R 3 are as defined above, and R 1 and R 2 are not both hydrogen maybe obtained from a compound of formula 1 wherein one of R 1 or R 2 is hydrogen by conversion to the corresponding, wherein M + represents an alkali metal such as lithium, sodium or potassium, in an inert solvent such as TETRAHYDROFURAN, DMSO or the like, and subsequently reacting it with a compound of formula R 2 --X wherein R 2 is as previously defined, and X is the radical of a reactive ester, a halogen atom, methanesulfonyloxy, trifluoromethanesulfonyloxy or an aromatic sulfonyloxy group. ##STR5## Compounds of formula 1 ##STR6## wherein R 1 through R 3 are as defined above, may be obtained from a compound of formula 2 by deoxygenation with reagents such as phosphorus trichloride in an inert solvent such as chloroform, or Lawessons reagent in an inert solvent such as toluene at some temperature between room temperature and the boiling point of the solvent. ##STR7## Compounds of formula 2 ##STR8## wherein R 1 through R 3 are as defined above, may be obtained from a compound of formula 3 wherein R 1 through R 3 are as defined above, and R 4 is a chloro or bromo substituent, by conversion to the corresponding metal salt 4, wherein M + represents an alkali metal such as lithium, sodium or potassium, in an inert solvent such as TETRAHYDROFURAN, DMSO or the like, and subsequently reacting the cyclized intermediate 5 with a compound of formula R 1 --X wherein R 1 is as previously defined and X is the radical of a reactive ester, a halogen atom, methanesulfonyloxy, trifluoromethanesulfonyloxy or an aromatic sulfonyloxy group, or by reacting 5 with a compound of formula R 1 --S--S--R 1 wherein R 1 is as previously defined. ##STR9## Compounds of formula 3 ##STR10## wherein R 3 and R 4 are as described above may be obtained from a compound of formula 7 by reaction with hydrogen peroxide in acetic acid at the boiling point of the solvent. 2-Chloronicotinic acid amides of general formula 7 can be obtained by condensation of 2-methylnicotinic acid chloride with an appropriately substituted 3-amino-2-halopyridine, under well known reaction conditions. All the other starting materials needed to prepare compounds of the formula 1 are known from the literature, or may be purchased, or may be obtained by procedures known from the literature. Formation Of Salts And Other Derivatives Compounds of formula 1 may, if desired, be converted into their non-toxic, pharmaceutically acceptable addition salts by conventional methods; for example, by dissolving a compound of formula 1 in a suitable solvent and treating the solution with one or more molar equivalents of the desired acid or base, as appropriate. The invention also comprises such salts. Examples of inorganic and organic acids which may form nontoxic, pharmaceutically acceptable acid addition salts with a compound of the formula 1 are the following: hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid, methanesulfonic acid, tartaric acid, fumaric acid, acetic acid, and the like. Examples of inorganic and organic bases which may form nontoxic, pharmaceutically acceptable basic addition salts with a compound of the formula 1 are the following: sodium hydroxide, potassium hydroxide, magnesium hydroxide, ammonia, tromethamine, and the like. Compounds of formula 1 may form addition salts with one molar equivalent of the acid or base, as appropriate. It will be obvious to those skilled in the art that in some instances the reactions described in Methods A to H cannot be effected in the presence of reactive intermediates incompatible with the reaction conditions. In such cases, the reactive substituent must first be derivatized via known per se methods to contain a suitable protective group, which can then be subsequently removed. Biological Properties The above described compounds of formula 1 possess inhibitory activity against HIV-1 reverse transcriptase. By inhibiting HIV-1 reverse transcriptase, they ultimately inhibit or suppress the ability of the virus to integrate its genome into the genome of potential host cells, which, in turn, inhibits or suppresses viral replication. When administered in suitable dosage forms, alone or in combination with other anti-virals, immunomodulators, antibiotics, anti-infectives, or vaccines, they are, thus, useful in the prevention or treatment of HIV-1 infection. Another aspect of the invention, therefore, is a method for preventing or treating HIV-1 infection which comprises administering to a human being, exposed to or infected by HIV-1, a prophylactically or therapeutically effective amount of a novel compound of formula 1, as described above. As the term is used herein, infection by HIV-1 constitutes the replication of HIV-1 in a human host. As the term is used herein, the treatment of HIV-1 infection comprises the partial or total inhibition or suppression of replication of HIV-1 in a human host in whom replication of the virus has already begun to take place. As the term is used herein, the prevention of HIV-1 infection comprises the complete prevention of the establishment of viral replication in a human host who has been exposed to HIV-1 but in whom replication of the virus has not yet begun to take place. The compounds of the present invention are effective agents for the treatment of HIV-1 infection by virtue of their ability to partially or totally inhibit or suppress replication of HIV-1 in an infected human host. When used to treat HIV-1 infection, the compounds of the present invention can be administered either before or after the onset of clinical manifestations of HIV-1 infection, such as ARC or AIDS. The compounds of the present invention are effective for the prevention of HIV-1 infection in humans, by virtue of their ability to prevent the establishment of viral replication in a human host who has been exposed to HIV-1 but in whom replication of the virus has not yet begun to take place. The compounds of formula 1 may be administered in single or divided doses by the oral, parenteral or topical routes. A suitable oral dosage for a compound of formula 1 would be in the range of about 100 mg to 3 g per day. A preferred oral dosage for a compound of formula 1 would be the maximum tolerated dose, which would typically be in the range of between about 200 mg and 2 g per day. In parenteral formulations, a suitable dosage unit may contain from 0.1 to 250 mg of said compounds, preferably 1 mg to 200 mg, whereas for topical administration, formulations containing 0.01 to 1% active ingredient are preferred. It should be understood, however, that the dosage administration from patient to patient will vary and the dosage for any particular patient will depend upon the clinician's judgement, who will use as criteria for fixing a proper dosage the size and condition of the patient as well as the patient's response to the drug. When the compounds of the present invention are to be administered by the oral route, they may be administered as medicaments in the form of pharmaceutical preparations which contain them in association with a compatible pharmaceutical carrier material. Such carrier material can be an inert organic or inorganic carrier material suitable for oral administration. Examples of such carrier materials are water, gelatin, talc, starch, magnesium stearate, gum arabic, vegetable oils, polyalkylene-glycols, petroleum jelly and the like. The pharmaceutical preparations can be prepared in a conventional manner and finished dosage forms can be solid dosage forms, for example, tablets, dragees, capsules, and the like, or liquid dosage forms, for example solutions, suspensions, emulsions and the like. The pharmaceutical preparations may be subjected to conventional pharmaceutical operations such as sterilization. Further, the pharmaceutical preparations may contain conventional adjuvants such as preservatives, stabilizers, emulsifiers, flavor-improvers, wetting agents, buffers, salts for varying the osmotic pressure and the like. Solid carrier material which can be used include, for example, starch, lactose, mannitol, methyl cellulose, microcrystalline cellulose, talc, silica, dibasic calcium phosphate, and high molecular weight polymers (such as polyethylene glycol). For parenteral use, a compound of formula 1 can be administered in an aqueous or non-aqueous solution, suspension or emulsion in a pharmaceutically acceptable oil or a mixture of liquids, which may contain bacteriostatic agents, antioxidants, preservatives, buffers or other solutes to render the solution isotonic with the blood, thickening agents, suspending agents or other pharmaceutically acceptable additives. Additives of this type include, for example, tartrate, citrate and acetate buffers, ethanol, propylene glycol, polyethylene glycol, complex formers (such as EDTA), antioxidants (such as sodium bisulfite, sodium metabisulfite, and ascorbic acid), high molecular weight polymers (such as liquid polyethylene oxides) for viscosity regulation and polyethylene derivatives of sorbitol anhydrides. Preservatives may also be added if necessary, such as benzoic acid, methyl or propyl paraben, benzalkonium chloride and other quaternary ammonium compounds. The compounds of this invention may also be administered as solutions for nasal application and may contain in addition to the compounds of this invention suitable buffers, tonicity adjusters, microbial preservatives, antioxidants and viscosity-increasing agents in an aqueous vehicle. Examples of agents used to increase viscosity are polyvinyl alcohol, cellulose derivatives, polyvinylpyrrolidone, polysorbates or glycerin. Microbial preservatives added may include benzalkonium chloride, thimerosal, chloro-butanol or phenylethyl alcohol. Additionally, the compounds provided by the invention can be administered by suppository. The compounds of the invention may be administered either alone or in combination with other anti-virals, immunomodulators, antibiotics, anti-infectives, or vaccines. For example the compounds of the invention may be administered in combination with one or more of the known nucleoside analog HIV reverse transcriptase inhibitors, such as AZT, ddI and ddC, other non-nucleoside HIV reverse transcriptase inhibitors, or HIV protease inhibitors. As stated before, the compounds provided by the invention inhibit the enzymatic activity of HIV-1 RT. Based upon testing of these compounds, as described below, it is known that they inhibit the RNA-dependent DNA polymerase activity of HIV-1 RT. It is known (data not shown) that they also inhibit the DNA-dependent DNA polymerase activity of HIV-1 RT. Utilizing the Reverse Transcriptase (RT) Assay described below, compounds can be tested for their ability to inhibit the RNA-dependent DNA polymerase activity of HIV-1 RT. Certain specific compounds described in the Examples which appear below, were so tested. The results of this testing appear in Table I, below. REVERSE TRANSCRIPTASE (RT) ASSAYS Assay Theory: Among the enzymes for which Human Immunodeficiency Virus (HIV-1) encodes is a reverse transcriptase (1), so-named because it transcribes a DNA copy from an RNA template. This activity can be quantitatively measured in a cell-free enzyme assay, which has been previously described (2), and is based upon the observation that reverse transcriptase is able to use a synthetic template poly r(C) primed with oligo d(G)! to transcribe a radio-labelled, acid-precipitable DNA strand utilizing 3 H-dGTP as a substrate. The assay described below utilizes the wild type (WT) enzyme, which is the predominant form of the enzyme observed in patients infected with HIV-1. Utilization of mutant RT enzymes (Y181C and Y181L, prepared by site-directed mutagenesis in which the tyrosine residue at codon 181 has been replaced by a cysteine or a leucine residue, respectively) and analogous assay conditions allows compounds to be evaluated for their effectiveness at inhibiting these mutant enzymes. Materials: a) Preparation of the wild type enzyme Reverse transcriptase enzyme from the LAV strain of Human Immunodeficiency Virus (HIV-1) (1) was isolated from the bacterial strain JM109 (3) expressing the DNA clone pBRTprtl+ (2) which is under the control of the lac promotor in the expression vector pIBI21 (4). An overnight culture grown in 2XYT medium (37° C., 225 rpm) (5) supplemented with 100 μg/mL ampicillin for positive selection is inoculated at a 1:40 dilution into M9 medium supplemented with 10 μg/mL thiamine, 0.5% casamino acids, and 50 μg/mL ampicillin (5). The culture is incubated (37° C., 225 rpm) until it reaches an OD540 of 0.3-0.4. At that time the repressor inhibitor IPTG (isopropyl β-D-thiogalactopyranoside) is added to 0.5 mM, and the mixture is incubated for 2 additional hours. Bacteria are pelleted, resuspended in a 50 mM Tris, 0.6 mM EDTA, 0.375M NaCl buffer and digested by the addition of lysozyme (1 mg/mL) for 30 minutes on ice. The cells are lysed by the addition of 0.2% NP-40 and brought to 1M NaCl. After removal of the insoluble debris by centrifugation, the protein is precipitated by the addition of 3 volumes of saturated aqueous ammonium sulfate. The enzyme is pelleted, resuspended in RT buffer (50 mM Tris pH 7.5, 1 mM EDTA, 5 mM DTT, 0.1% NP-40, 0.1M NaCl, and 50% glycerol), and stored at -70° C. for further use. b) Composition of 2× concentrated stock reaction mixture ______________________________________ 2X MixStock Reagent Concentration______________________________________1M Tris pH 7.4 100 mM1M dithiothrietol 40 mM1M NaCl 120 mM1% Nonidet P-40 0.1%1M MgCl 4 mM poly r(C)/oligo d(G)! (5:1) 2 μg/mL.sup.3 H-DgTP (81 μM) 0.6 μM______________________________________ Assay Procedure: The 2× concentrated stock reaction mixture is aliquoted and stored at -20° C. The mixture is stable and thawed for use in each assay. This enzyme assay has been adapted to a 96 well microtiter plate system, and has been previously described (6). Tris buffer (50 mM, pH 7.4), vehicle (solvent diluted to match the compound dilution), or compounds in vehicle are dispensed into 96-well microtiter plates (10 μL/well; 3 wells/compound). The HIV-1 RT enzyme is thawed, diluted in 50 mM Tris pH 7.4 so that fifteen μL of diluted enzyme contain 0.001 Unit (one unit is that amount of enzyme to transform 1 micromole of substrate per minute at 25° C.), and fifteen μL are dispensed per well. Twenty μL of 0.12-0.5M EDTA are added to the first three wells of the microtiter plate. EDTA chelates the Mg ++ present and prevents reverse transcription. This group serves as background polymerization which is subtracted from all other groups. Twenty-five μl of the 2× reaction mixture are added to all wells and the assay is allowed to incubate at room temperature for 60 minutes. The assay is terminated by precipitating the DNA in each well with 50 μL of 10% trichloracetic acid (TCA) (10% w/v) in sodium pyrophosphate (1% w/v). The microtiter plate is incubated for 15 minutes at 4° C. and the precipitate is fixed onto #30 glass fiber paper (Schleicher & Schuell) using a Skatron semi-automatic harvester. The filters are then washed with additional TCA (5%) containing sodium pyrophosphate (1%), rinsed with aqueous ethanol (70%), dried, and transferred to scintillation vials (6). Each vial receives 2 mL of scintillation cocktail and is counted in a Beckman beta counter. The calculation for percent inhibition is as follows: ##EQU1## References: 1. Benn, S., et al., Science 230:949, 1985 2. Farmerie, W. G. et. al., Science 236:305, 1987 3. Yanisch-Perron, C., Viera, J., and Messing, J., Gene 33:103, 1985 4. International Biotechnologies, Inc., New Haven, Conn. 06535 5. Maniatis, T, Fritsch, E. F., and J. Sambrook, eds. Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory, 1982 6. Spira, T., et. al. J. Clinical Microbiology, 25:97, 1987. TABLE I______________________________________ Reverse Transciptase AssayCompound of % inhibition (1 μM)Example No WT Y181C______________________________________1 68% 34%2 62% 14%3 64% 0%4 68% 9%5 62% 18%6 62% 15%7 75% 21%8 84% 24%9 66% 26%10 91% 46%11 80% 33%12 41% 30%13 80% 56%______________________________________ EXAMPLES The following examples further illustrate the present invention and will enable others skilled in the art to understand it more completely. It should be understood, however, that the invention is not limited to the particular examples given below. Example 1 5,11-Dihydro-11-ethyl-5-methyl-10-oxo-6H-dipyrido 3,2-b:2',3'-e!azepin-6-on ##STR11## N-(2-chloro-3-pyridinyl)-2-methylnicotinamide. To a suspension of potassium 2-methylnicotinate (1.82 g) in chloroform (30 mL) was added thionyl chloride (2.0 mL). The mixture was stirred overnight at room temperature under a drying tube. The solvent was evaporated and the residue was taken up in ethyl acetate. 3-Amino-2-chloropyridine (1.28 g) was added followed by diisopropylethylamine (4.0 mL). The reaction mixture was stirred at room temperature under a drying tube for 3 hours. The mixture was diluted with chloroform, washed with water, dried (Na 2 SO 4 ), filtered, and evaporated Chromatography of the residue over silica gel (ethyl acetate/hexane) gave N-(2-chloro-3-pyridinyl)-2-methylnicotinamide (1.94 g). N-(2-chloro-3-pyridinyl)-N-methyl-2-methylnicotinamide. To a stirred solution of N-(2-chloro-3-pyridinyl)-2-methylnicotinamide (1.48 g) in DMSO (20 mL) was added NaH (60% in oil, 0.26 g). After 20 minutes, methyl iodide (0.45 mL) was added, and stirring was continued for 30 minutes. The mixture was diluted with ethyl acetate, washed with water, dried (Na 2 SO 4 ), filtered, and evaporated. Chromatography of the residue over silica gel (ethyl acetate/hexane) gave N-(2-chloro-3-pyridinyl)-N-methyl-2-methylnicotinamide (1.51 g). N-(2-chloro-3-pyridinyl)-N-methyl-2-methylnicotinamide N-oxide. A mixture of N-(2-chloro-3-pyridinyl)-N-methyl-2-methylnicotinamide (1.86 g) and H 2 O 2 (30%, 5 mL) in acetic acid (10 mL) was heated at 110° C. for 75 minutes. The solvents were evaporated under reduced pressure. Chromatography of the residue over basic alumina (chloroform/ethanol) gave N-(2-chloro-3-pyridinyl)-N-methyl-2-methylnicotinamide N-oxide as an oil which crystallized on trituration with isopropyl ether/ethyl acetate, (1.42 g). 5,11-dihydro-11-ethyl-5-methyl-10-oxodipyrid 3,2-b:2',3'-e!azepine-6-one. To a stirred solution of N-(2-chloro-3-pyridinyl)-N-methyl-2-methylnicotinamide N-oxide (1.11 g) in tetrahydrofuran (15 mL) under nitrogen, cooled on ice, was added dropwise potassium tert-butoxide (1M in tetrahydrofuran, 8.5 mL) over 5 minutes. The mixture was allowed to warm to room temperature, stirred for 30 minutes, and ethyl iodide (0.35 mL) was added. After 90 minutes, the mixture was diluted with chloroform, and washed with water. The aqueous phase was back extracted with chloroform and the combined organic phase was dried (Na 2 SO 4 ), filtered, and evaporated. Chromatography of the residue over basic alumina (methylene chloride/ethanol) gave 5,11-dihydro-11-ethyl-5-methyl-10-oxodipyrid 3,2-b:2',3'-e!azepine-6-one (0.75 g). Example 2 5,11-Dihydro-11-ethyl-5-methyldipyrido 3,2-b:2',3'-e!azepine-6-one ##STR12## To a solution of 5,11-dihydro-11-ethyl-5-methyl-10-oxodipyrido 3,2-b:2',3'-e!azepine-6-one (0.328 g) in chloroform (10 mL) cooled on ice was added phosphorus trichloride (1.0 mL). The mixture was heated under reflux for 10 minutes, cooled, and added to aqueous NaOH (15% solution, 10 mL). Chloroform (50 mL) was added, and the organic phase was separated, dried (Na 2 SO 4 ), filtered, and evaporated. Chromatography of the residue over silica gel (ethyl acetate/ethanol) gave 5,11-dihydro-11-ethyl-5-methyldipyrido 3,2-b:2',3'-e!azepine-6-one (0.209 g). Example 3 5,11-Dihydro-11-propyl-5-methyldipyrido 3,2-b:2',3'-e!azepine-6-one ##STR13## 5,11-dihydro-11-propyl-5-methyl-10-oxodipyrid 3,2-b:2',3'-e!azepine-6-one To a stirred solution of N-(2-chloro-3-pyridinyl)-N-methyl-2-methylnicotinamide N-oxide (0.553 g) in tetrahydrofuran (10 mL) under nitrogen, cooled on ice, was added dropwise sodium bis(trimethylsilyl)amide (1M in tetrahydrofuran, 5 mL). After 5 minutes the mixture was allowed to warm to room temperature, and propyl iodide (0.30 mL) was added. After 3 hours, water was added, the mixture was diluted with chloroform, and the organic phase was separated, washed, dried (Na 2 SO 4 ), filtered, and evaporated. Chromatography of the residue over basic alumina (chloroform/ethanol)) gave 5,11-dihydro-11-propyl-5-methyl-10-oxodipyrid 3,2-b:2',3'-e!azepine-6-one (0.255 g) which was used directly in the next step. 5,11-dihydro-11-propyl-5-methyl-dipyrid 3,2-b:2',3'-e!azepine-6-one To a solution of 5,11-dihydro-11-propyl-5-methyl-10-oxodipyrido 3,2-b:2',3'-e!azepine-6-one (0.255 g) in chloroform (10 mL) cooled on ice was added phosphorus trichloride (0.3 mL). The mixture was heated under reflux for 10 minutes, cooled, and quenched with aqueous NaOH (5% solution). Chloroform (50 mL) was added, and the organic phase was separated, dried (Na 2 SO 4 ), filtered, and evaporated. Chromatography of the residue over silica gel (ethyl acetate/hexane) gave 5,11-dihydro-11-propyl-5-methyldipyrido 3,2-b:2',3'-e!azepine-6-one (0.10 g). Example 4 5,11-Dihydro-11-ethyl-11-methyl-5-methyldipyrido 3,2-b:2',3'-e!azepine-6-one ##STR14## To a solution of 5,11-dihydro-11-ethyl-5-methyldipyrido 3,2-b:2',3'-e!azepine-6-one (0.10 g) in DMSO (1 mL) stirred under nitrogen was added potassium tert-butoxide (1M in tetrahydrofuran, 0.5 mL). After 3 minutes, methyl iodide (0.1 mL) was added, and the mixture was stirred for 10 minutes. Ethyl acetate was added, and the mixture was washed with water, dried, filtered, and evaporated. The residue was fractionated by preparative layer chromatography (developer chloroform/ethanol) to give 5,11-dihydro-11-ethyl-11-methyl-5-methyldipyrido 3,2-b:2',3 '-e!azepine-6-one (0.006 g). Example 5 5,11-Dihydro-11-diethyl-5-methyldipyrido 3,2-b:2',3'-e!azepine-6-one ##STR15## To a stirred solution of N-(2-chloro-3-pyridinyl)-N-methyl-2-methylnicotinamide (0.523 g) in tetrahydrofuran (10 mL) under nitrogen, cooled to -10° C., was added dropwise sodium bis(trimethylsilyl)amide (1M in tetrahydrofuran, 5 mL). The mixture was allowed to warm to room temperature, and after 15 minutes ethyl iodide (0.30 mL) was added. After 15 minutes, methanol (1 mL) and ethyl acetate were added. The mixture was washed, dried (Na 2 SO 4 ), filtered, and evaporated. Chromatography of the residue over silica gel (ethyl acetate/hexane) gave 5,11-dihydro-11-diethyl-5-methyl-10-oxodipyrid 3,2-b:2',3'-e!azepine-6-one (0.098 g). Example 6 5,11-Dihydro-11-spirocyclopentyl-5-methyldipyrido 3,2-b:2',3'-e!azepine-6-one ##STR16## 5,11-dihydro-5-methyl-10-oxodipyrid 3,2-b:2',3'-e!azepine-6-one To a stirred solution of N-(2-chloro-3-pyridinyl)-N-methyl-2-methylnicotinamide N-oxide (1.02 g) in tetrahydrofuran (20 mL) under argon at room temperature, was added dropwise potassium tert-butoxide (1M in tetrahydrofuran, 7 mL). After 30 minutes, water was added, the mixture was diluted with methylene chloride, and the organic phase was separated, washed, dried (Na 2 SO 4 ), filtered, and evaporated. Trituration of the residue gave 5,11-dihydro-5-methyl-10-oxodipyrid 3,2-b:2',3'-e!azepine-6-one (0.76 g) which was used directly in the next step. 5,11-dihydro-5-methyl-10-dipyrid 3,2-b:2',3'-e!azepine-6-one To a solution of 5,11-dihydro-5-methyl-10-oxodipyrido 3,2-b:2',3'-e!azepine-6-one (0.199 g) in chloroform (3 mL) was added Lawessons reagent (0.140 g). The mixture was stirred for 30 minutes. Chromatography of the reaction mixture directly over silica gel (ethyl acetate/ethanol) gave 5,11-dihydro-5-methyldipyrido 3,2-b:2',3'-e!azepine-6-one (0.172 g). 5,11-Dihydro-11-spirocyclopentyl-5-methyldipyrido 3,2-b:2',3'-e!azepine-6-one. To a solution of 5,11-dihydro-5-methyldipyrido 3,2-b:2',3'-e!azepine-6-one (0.069 g) in DMSO (0.6 mL) stirred at room temperature, was added potassium tert-butoxide (1M in tetrahydrofuran, 0.4 mL). After 2 minutes 1,4-diiodobutane (0.11 g) in DMSO (0.3 mL) was added. After 10 minutes, additional potassium tert-butoxide (0.4 mL) was added, and the mixture was stirred for 1 hour. The mixture was diluted with ethyl acetate, washed with water, dried, filtered, and evaporated. Fractionation of the residue by preparative layer chromatography gave 5,11-Dihydro-11-spirocyclopentyl-5-methyldipyrido 3,2-b:2',3'-e!azepine-6-one (0.019 g). Example 7 5,11-Dihydro-11-ethyl-2-methoxy-5-methyl-10-oxodipyrido 3,2-b:2',3'-e!azepine-6-one ##STR17## N-(2-Bromo-6-methoxy-3-pyridinyl)-2-methylnicotinamide To a suspension of potassium 2-methylnicotinate (1.96 g) in chloroform (30 mL) was added thionyl chloride (2.5 mL). The mixture was stirred overnight at room temperature under a drying tube. Diisopropylethylamine (5 mL) was added followed by 3-amino-2-bromo-6-methoxypyridine (2.25 g). After 10 minutes additional diisopropylethylamine (5 mL) was added. After 2 hours the mixture was diluted with chloroform, washed with water, dried (Na 2 SO 4 ,) filtered, and evaporated. Chromatography of the residue over silica gel (chloroform/methanol) gave N-(2-bromo-6-methoxy-3-pyridinyl)-2-methylnicotinamide (2.80 g). N-(2-Bromo-6-methoxy-3-pyridinyl)-N-methyl-2-methylnicotinamide N-oxide To a stirred solution of N-(2-bromo-6-methoxy-3-pyridinyl)-2-methylnicotinamide (1.61 g) in DMSO (5 mL) was added sodium bis(trimethylsilyl)amide (1M in tetrahydrofuran, 5.5 mL) followed by methyl iodide (0.25 mL). After 15 minutes, the mixture was diluted with ethyl acetate, washed with water, dried (Na 2 SO 4 ), filtered, and evaporated. The residue was dissolved in acetic acid (5 mL) and 32% peracetic acid (5 mL), and was heated at 100° C. for 1 hour. The solvents were evaporated under reduced pressure. The residue was taken up in chloroform and washed with 5% aqueous sodium hydroxide. The organic phase was dried, filtered, and evaporated to give N-(2-bromo-6-methoxy-3-pyridinyl)-N-methyl-2-methylnicotinamide N-oxide which crystallized from ethyl acetate, (1.51 g). 5,11-dihydro-11-ethyl-2-methoxy-5-methyl-10-oxodipyrid 3,2-b:2',3'-e!azepine-6-one To a stirred solution of N-(2-bromo-6-methoxy-3-pyridinyl)-N-methyl-2-methylnicotinamide N-oxide (0.655 g) in tetrahydrofuran (15 mL) under argon was added dropwise potassium tert-butoxide (1M in tetrahydrofuran, 4 mL). The mixture was stirred at room temperature for 45 minutes, and ethyl iodide (0.2 mL) was added. After 1 hour, the mixture was diluted with chloroform, washed with water, dried (Na 2 SO 4 ), filtered, and evaporated. Chromatography of the residue over silica gel (methylene chloride/ethanol) 5,11-dihydro-11-ethyl-2-methoxy-5-methyl-10-oxodipyrid 3,2-b:2',3'-e!azepine-6-one which crystallized on trituration with ether (0.416 g). Example 8 5,11-Dihydro-11-ethyl-2-methoxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one ##STR18## 5,11-dihydro-11-ethyl-2-methoxy-5-methyl-10-oxodipyrid 3,2-b:2',3'-e!azepine-6-one. A mixture of 5,11-dihydro-11-ethyl-2-methoxy-5-methyl-10-oxodipyrid 3,2-b:2',3'-e!azepine-6-one (0.041 g), and Lawessons reagent (0.030 g) in xylene (1 mL) was heated at 100 ° C. in a sealed tube for 2 hours. The mixture was fractionated directly by preparative layer chromatography (developer ethyl acetate/hexane 1/1) to give 5,11-dihydro-11-ethyl-2-methoxy-5-methyl-10-dipyrid 3,2-b:2',3'-e!azepine-6-one (0.022 g). Example 9 5,11-Dihydro-11-diethyl-2-methoxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one ##STR19## 5,11-Dihydro-11-diethyl-2-methoxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one To a stirred solution of 5,11-dihydro-11-ethyl-2-methoxy-5-methyl-10-dipyrid 3,2-b:2',3'-e!azepine-6-one (0.032 g) in DMSO (1 mL) was added potassium tert-butoxide (1M in tetrahydrofuran, 0.3 mL). After 5 minutes, ethyl iodide (0.1 mL) was added. After 20 minutes, the mixture was diluted with ethyl acetate, washed with water, dried, filtered, and evaporated. Fractionation of the residue by preparative layer chromatography (developer, ethyl acetate/hexane) gave 5,11-dihydro-11-diethyl-2-methoxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one (0.024 g). Example 10 5,11-Dihydro-11-methylthio-2-methoxy-5-methyl-10-oxodipyrido 3,2-b:2',3'-e!azepine-6-one ##STR20## To a stirred solution of N-(2-bromo-6-methoxy-3-pyridinyl)-N-methyl-2-methylnicotinamide N-oxide (0.709 g) in tetrahydrofuran (15 mL) was added sodium bis(trimethylsilyl)amide (1M in tetrahydrofuran, 6 mL). After 2 hours, dimethyldisulfide (0.4 mL) was added and the mixture was stirred at room temperature overnight. The mixture was diluted with chloroform, washed with water, dried, filtered, and evaporated. Chromatography of the residue over silica gel (chloroform/ethanol) gave 5,11-dihydro-11-methylthio-2-methoxy-5-methyl-10-oxodipyrido 3,2-b:2',3'-e!azepine-6-one (0.183 g). Example 11 5,11-Dihydro-11-methylthio-2-methoxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one ##STR21## A mixture of 5,11-dihydro-11-methylthio-2-methoxy-5-methyl-10-oxodipyrido 3,2-b:2',3'-e!azepine-6-one (0.067 g) and Lawessons reagent (0.044 g) in xylene (3 mL) was stirred and heated at 90° C. for 20 minutes. The mixture was fractionated directly by preparative layer chromatography (developer, ethyl acetate/hexane) to give 5,11-dihydro-11-methylthio-2-methoxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one (0.061 g). Example 12 5,11-Dihydro-11-methyl-11-methylthio-2-methoxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one ##STR22## To a solution of 5,11-dihydro-11-methylthio-2-methoxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one (0.031 g) in DMSO (0.5 mL) stirred under argon was added potassium tert-butoxide (1M in tetrahydrofuran, 0.012 mL). After 1 minute, methyl iodide (0.05 mL) was added. After 5 minutes the mixture was diluted with ethyl acetate, washed with water, dried, filtered and evaporated. Fractionation of the residue by preparative layer chromatography (developer, ethyl acetate/hexane) gave 5,11-dihydro-11-methyl-11-methylthio-2-methoxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one (0.029). Example 13 5,11-Dihydro-11-ethyl-2-(4-pyrazolyl)-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one ##STR23## 5,11-Dihydro-11-ethyl-2-trifluoromethanesulfonyloxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one A solution of 5,11-dihydro-11-ethyl-2-methoxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one (0.181 g) in acetic acid (1 mL) and 48% HBr in acetic acid (1 mL) was heated at 110° C. for 10 minutes. The mixture was cooled, neutralized with saturated sodium bicarbonate, and extracted with chloroform. The organic phase was dried, filtered and evaporated to give 5,11-dihydro-11-ethyl-2-hydroxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one (0.176 g) which was used directly in the next reaction. To a solution of 5,11-dihydro-11-ethyl-2-hydroxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one (0.176 g) in chloroform (10 mL) cooled on ice was added triethylamine (0.25 mL) followed by triflic anhydride (0.2 mL). After 10 minutes, the mixture was diluted with ethyl acetate, washed with water, dried, filtered, and evaporated. Chromatography of the residue over silica gel (ethyl acetate/hexane) gave 5,11-dihydro-11-ethyl-2-trifluoromethanesulfonyloxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one (0.165 g). 5,11-Dihydro-11-ethyl-2-(4-pyrazolyl)-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one A mixture of 5,11-dihydro-11-ethyl-2-trifluoromethanesulfonyloxy-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one (0.084 g), 4-tributylstannylpyrazole (0.096 g), lithium chloride (0.052 g) and Pd(Ph 3 P) 2 Cl 2 (0.009 g) in dimethylformamide (1 mL) was heated at 120° C. in a sealed tube 16 hours. The mixture was diluted with ethyl acetate, washed with water, dried, filtered and evaporated. Chromatography of the residue over silica gel (ethyl acetate/hexane) gave 5,11-dihydro-11-ethyl-2-(4-pyrazolyl)-5-methyl-dipyrido 3,2-b:2',3'-e!azepine-6-one (0.010 g). Example A Capsules or Tablets ______________________________________A-1 A-2Ingredients Quantity Ingredients Quantity______________________________________Compound of Ex. 12 250 mg Compound of Ex. 12 50 mgStarch 160 mg Dicalcium Phosphate 160 mgMicrocrys. Cellulose 90 mg Microcrys. Cellulose 90 mgNa Starch Glycolate 10 mg Stearic acid 5 mgMagnesium Stearate 2 mg Sodium Starch Glycolate 10 mgFumed colloidal silica 1 mg Fumed colloidal silica 1 mg______________________________________ The compound of Example 13 is blended into a powder mixture with the premixed excipient materials as identified above with the exception of the lubricant. The lubricant is then blended in and the resulting blend compressed into tablets or filled into hard gelatin capsules. Example B Parenteral Solutions ______________________________________Ingredients Quantity______________________________________Compound of 500 mgExample 12Tartaric acid 1.5 gBenzyl Alcohol 0.1% by weightWater for injection q.s. to 100 mL______________________________________ The excipient materials are mixed with the water and thereafter the compound of Example 13 is added. Mixing is continued until the solution is clear. The pH of this solution is adjusted to 3.0 and is then filtered into the appropriate vials or ampoules and sterilized by autoclaving. Example C Nasal Solutions ______________________________________Ingredients Quantity______________________________________Compound of 100 mgExample 12Citric acid 1.92 gBenzalkonium 0.025% by weightchlorideEDTA 0.1% by weightPolyvinylalcohol 10% by weightWater q.s to 100 mL______________________________________ The excipient materials are mixed with the water and thereafter the compound of Example 13 is added and mixing is continued until the solution is clear. The pH of this solution is adjusted to 4.0 and is then filtered into the appropriate vials or ampoules.
There are disclosed compounds of the formula 1 ##STR1## wherein X is an oxygen atom or nothing and R1, R2 and R3 are as defined in the specification, useful in the prevention or treatment of HIV infection.
2
TECHNICAL FIELD [0001] The present invention relates to a method for preparing pearlescent pigment, in particular to a method for preparing pearlescent pigment without free particles. BACKGROUND ART [0002] A process by which pigment with pearlescent effect is prepared using sheet-like materials as a substrate and single-layer or multilayer oxides as a coating has been adopted for several decades, is highly mature, and has a large amount of patents. A process that forced hydrolysis coating is performed through water-soluble metal salt at a preset PH value is a commonly used technique, since the water-soluble metal salt is acidic generally, and alkali must be added during continuous addition of the water-soluble metal salt to balance the PH value, otherwise the hydrolysis cannot be performed continuously. Metal hydroxides, such as NaOH and KOH, are mainly used to neutralize acid and alkali currently. Aqueous ammonia (NH 3 .H 2 O), sodium carbonate (Na 2 CO 3 ) or the like can also be used to control the PH value to perform hydrolysis coating. The abovementioned alkalis all can dissolve in water, and are generally made into a water solution before added to a reaction kettle in production. Even though added in a solid form, the water-soluble alkali is dissolved to form a solution after entering the reaction kettle, and also provides required hydroxyl (OH − ) to neutralize the acid (H + ) to achieve a purpose of maintaining a stable PH value. The process has the following defects: when the alkali enters the reaction kettle, local overhigh alkali concentration occurs unavoidably, and in addition to neutralizing the acid, the local overhigh-concentration alkali (OH − ) may further combine with coating metal ions (such as Ti 4+ , TiO 2+ , Fe 3+ and Sn 4+ ) to produce metal hydroxide (or hydrated metal oxide) sediment, and does not completely coat the sheet-like substrate, thus forming free substances. Since the free substances have high absorption capability due to a small size (nanoscale generally) and a large specific surface area, the hydrolysis coating compete between the free particles and the sheet-like substrate subsequently. Once being formed, the free particles are removed only by subsequent steps of filtering, washing, gas flow classifying and the like, since the free particles can lower colourity of the pearlescent pigment and cause various problems during application. Even though the free particles can be reduced by stirring and a strict control of a feeding speed, the free particles cannot be eliminated completely by the foregoing process. SUMMARY OF THE INVENTION [0003] The present invention provides a novel technology that adopts water-insoluble materials to control a PH value, and prevents direct reaction of alkali and metal ions, preparing pearlescent pigment without free particles. Since the material added into a reaction kettle to neutralize an acid does not dissolve in water, OH − is not provided directly, avoiding local overhigh alkali (OH − ) concentration, and the material (such as MgO) for neutralizing the acid only reacts with an acid (H + ) rather than a metal ion (such as TiO 2+ ). Salt (such as MgCl 2 ) generated through reaction of the water-insoluble material (such as MgO) and acid may dissolve in water and be removed by subsequent filtering and washing, thus preparing high-quality pearlescent pigment without free particles. [0004] Thus, according to a first embodiment of the present invention, a method for preparing pearlescent pigment is provided, wherein the method comprises: A) in the presence of sheet-like substrates and at a set pH value which allows metal salt for coating to be hydrolyzed, performing hydrolysis coating by adding the metal salt for coating and inorganics simultaneously into water, wherein the inorganics does not dissolve in water but can dissolve through reacting with an acid, and the inorganics is used to adjust or maintain a pH value of a hydrolysis system. [0005] Preferably, relative to 1000 parts by weight of the sheet-like substrates, 350-1500 and preferable 450-1350 parts by weight of the metal salt and 300-1400, and preferable 400-1200 parts by weight of the inorganics are used. Preferably, the sheet-like substrates are used in a slurry form of 5-30wt % and preferably 10 to 15wt % (wt % based on solid). Preferably, the particle size of the sheet-like substrates is 10-60 micrometers. After hydrolysis coating, the thickness of the resulting coating is generally 10-100 nm, preferably 30-60 nm, and more preferably 40-50 nm. [0006] Preferably, the set pH value is within a range of 0.5-3, preferably 0.7-2.5, more preferably 0.8-2 and still more preferably 0.9-1.5 (for example 1, 1.1, 1.2 or 1.3). [0007] Preferably, the inorganics which does not dissolve in water but can dissolve through reacting with an acid is an alkaline-earth metal compound, and more preferably an alkaline-earth metal oxide or carbonate. The inorganics is used preferably in a form of a water solution or slurry of 5-30wt %, and more preferably 10-20wt %. The particle size of the inorganics is preferably below 200 meshes, and more preferably 200-250 meshes or 200-300 meshes. [0008] Generally, the foregoing method further comprises the following steps of: B) filtering, C) washing, D) drying and E) calcining. [0009] Preferably, the metal salt for coating is added in a form of a water solution; and/or, the inorganics that does not dissolve in water but can dissolve through reacting with the acid is added in a form of slurry formed in water. The metal salt is used at a concentration of preferably 1-4 mol/L, and more preferably 1.5-3 mol/L. [0010] Preferably, the adding rate of the inorganics that does not dissolve in water but can dissolve through reacting with the acid is controlled in the step A) so that the pH value of the hydrolysis system is kept stable or basically stable. [0011] Preferably, the sheet-like substrates in the present invention are selected from one or two or more of natural mica, synthetic mica, glass sheet, sheet-like aluminum oxide and sheet metal. [0012] Preferably, the metal salt for coating is selected from one or two or more of TiCl 4 , TiOCl 2 , FeCl 3 or SnCl 4 . [0013] More preferably, the inorganics is selected from magnesium oxide, magnesium hydroxide, calcium carbonate or a mixture thereof. [0014] Preferably, after calcined, the coating material becomes one of the following components: anatase TiO 2 , tin dioxide SnO 2 , rutile TiO 2 , hematite Fe 2 O 3 , TiO 2 +FeO 3 , SnO 2 +TiO 2 +Fe 2 O 3 , SnO 2 +Fe 2 O 3 , Ti and Fe mixed oxide, and Sn, Ti and Fe mixed oxide. [0015] The amount of the metal salt and inorganics can be determined by a color of a product to be coated, for example, when inorganics is MgO and metal salt is TiCl 4 , if a product is silver white, relative to 1000 parts by weight of the sheet-like substrates, 370-430 parts by weight (for example, 400 parts by weight) of the inorganics, and 420-480 parts by weight of the metal salt are adopted. Hereinafter, the color of the product vary from golden yellow to red, blue and green, with the amount of the inorganics and metal salt increasing successively. When the product is green, for example, relative to 1000 parts by weight of the sheet-like substrates, 1100-1300 parts by weight of the inorganics and 1300-1400 parts by weight of the metal salt are adopted. [0016] According to a second embodiment of the present invention, the pearlescent pigment obtained by the above method is provided. [0017] According to a third embodiment of the present invention, the use of the above-said pearlescent pigment in paints, coatings, printing ink, plastics, ceramic materials, leather coloration, wallpaper, powder coatings or cosmetics is provided. [0018] The advantages of the present invention are as follows: [0019] The pearlescent pigment obtained in the present invention almost has no free particles, with good quality, desirable color and finish degree. BRIEF DESCRIPTION OF THE DRAWINGS [0020] FIG. 1 is a situation where hydrolysis coating slurry samples prepared by a new process (left) of the present invention and that by a conventional process (right) are respectively placed in glass bottles after a certain time of resting and sedimentation. DETAILED DESCRIPTION OF THE INVENTION [0021] The following examples are used to make detailed description of, rather than limitation on, the present invention. EXAMPLE 1 [0022] 1000 kg natural mica substrates with particle diameters D 10 =10 μm, D 50 =25 μm, D 90 =60 μm are added to 10000L deionized water (the reaction kettle is 20000L), stirred and heated to 80° C., adjusting to pH value of 1.0 by using 1:1 hydrochloric acid. MgO slurry is prepared: 1000 kg 99% MgO is added to 5000L water and stirred to prepare a slurry with total solid concentration of 20%. A particle diameter of less than 200 mesh is chosen to prevent the prepared slurry from sedimentation. At the start of hydrolysis coating, a titanium solution pump and an MgO slurry pump are operated simultaneously, and the pH value is automatically controlled to 1.0 by using a pH meter. A titanium solution is formulated with TiCl 4 having purity of not less than 99% and water with a proportion of water to TiCl 4 of 1:1 to prepare a titanium tetrachloride solution with the concentration of 2 mol/L, which may generate HCl gas when diluting. The released HCl gas is absorbed with water to obtain hydrochloric acid. Enough hydrochloric acid is added to prevent the diluted TiCl 4 from hydrolytic spoilage. The pH value is constantly 1.0 by simultaneously pumping the titanium solution and MgO slurry to the reaction kettle. The added titanium solution constantly forms a coating on the mica substrates by hydrolysis, when the pH value is 1.0. After filtering, washing and calcining, pearlescent products having silvery white, iridescence and the like are obtained. The amount of the TiCl 4 solution determines the color of the final product to be golden yellow, orange, red, purple, blue, green and so on. [0000] Titanium solution MgO slurry with with the total solid TiO 2 coating Color of Mica, concentration of concentration of thickness, product kg 2 mol/L, liter 20%, liter nm Silvery white 1000 1800 (TiCl 4 with 2000 (MgO, 45 the purity of not 400 kg) less than 99%, 450 kg) Golden 1000 2800 3100 70 yellow Red 1000 3800 4200 95 Blue 1000 4600 5100 115 Green 1000 5400 (99% TiCl 4 , 6000 (MgO, 135 1350 kg) 1200 kg) [0023] Compared with a conventional process (controlling pH value of the hydrolyzed coating with a base solution such as sodium hydroxide), the present invention provides a notable improvement in both lightness and chromaticity of products obtained through the new process thereof, and water consumption is saved by more than a half when filtering and watering. All these indicate that no free particles are generated in the new process when hydrolyzing; therefore, it is easier to filter and wash, and the product has better quality. [0024] Another method showing that no free particles are generated in the products obtained by using the new process comprises: respectively placing hydrolyzed coatings obtained by using the new process and conventional process in glass bottles. An upper mother solution (left) of the hydrolyzed coating slurry samples prepared by using the new process is more transparent than that of the conventional process after a certain time of standing and sedimentation (see FIG. 1 ). It can be seen from FIG. 1 that a mother solution in the upper layer in dispersion of the present invention is transparent while a mother solution in the upper layer in dispersion of the prior art is hazy. [0025] A method of evaluating sample quality by adopting a common coating swipe card or jet plate comprises: adding a proper amount of pearlescent powder samples (˜10%) to resin or paint, and forming coating through the coating swipe card or jet plate, and drying. Data of color and finish degree is measured with an X-Rite MA68 color difference meter. Data is shown by using a CIE L*, a*, b* system. L* indicates brightness, c value (c 2 =a 2 +b 2 ) indicates color concentration. EXAMPLE 2 [0026] Mica slurry, titanium solution and MgO slurry are prepared according to example 1, and a 20% SnCl 4 solution is prepared. 10 kg SnCl 4 is dissolved in 40 kg deionized water and pumped into a reaction kettle with a PH value of 1.0, then coated with titanium according to example 1, and the pH value is automatically controlled at 1.0 with MgO slurry. After a desired color is obtained, filtering, washing, drying and calcining are conducted to obtain a product . Taking a silver white product as examples, the weights of mica, 99% TiCl 4 , SnCl 4 and MgO are respectively 1000:450:10:400(kg). The thickness of the coating is about 45 nm. [0027] The obtained product is pearlescent powder without free TiO 2 . EXAMPLE 3 [0028] As described in example 1, mica slurry and MgO slurry are prepared and pH value is adjusted to 3.0. A 10% FeCl 3 solution is prepared by dissolving 1000 kg FeCl 3 in 9000L deionized water. a FeCl 3 solution and MgO slurry are simultaneously pumped and pH value is automatically controlled at 3.0. Pearlescent powder with metallic lustre can be obtained through filtering, washing and calcining after adding a proper amount of FeCl 3 solution to the reaction kettle. The amount of the FeCl 3 solution determines a color of the final product to be golden, orange, red, purple, blue, green and so on. Taking a brass golden product as an example, the amounts of mica, MgO and FeCl 3 by dry weight are respectively 1000:400:400(kg). The thickness of the final coating is about 50 nm. EXAMPLE 4 [0029] Mica slurry is prepared, and coated with SnO 2 according to example 2. With pH value adjusted to 3.0, iron coating is conducted according to example 3. Pearlescent powder with metallic lustre is obtained through filtering, washing and calcining. The amount of the FeCl 3 solution determines the color of the final product to be golden, orange, red, purple, blue, green and so on. Taking a brass golden product as an example, the actual amounts of mica, ferric trichloride (not titanium tetrachloride) and MgO and SnCl 4 are 1000:400:400:10(kg). The thickness of the final coating is about 50 nm. EXAMPLE 5 [0030] Titanium coating is performed according to example 1, and then iron coating is performed according to example 3 with pH value adjusted to 3.0. Pearlescent powder with two-layer coatings of titanium and iron with metallic lustre can be obtained through filtering, washing and calcining. The color of the final product is determined with the proportion and amount of titanium and iron. EXAMPLE 6 [0031] Titanium coating is performed according to example 2 and then iron coating is performed according to example 3 to produce pearlescent pigment with 2 layers of titanium and iron. EXAMPLE 7 [0032] A Ti liquid in example 1 and molten iron in example 3 are mixed according to the weight ratio of 100:10(Ti:Fe), mica slurry is prepared according to example 1, a PH value is adjusted to 2.5, and the pH value is automatically controlled at 2.5 by using MgO slurry so as to perform Ti-Fe mixed coating. EXAMPLE 8 [0033] Tin coating is performed according to example 2, and then, Ti—Fe mixed coating is performed according to example 7. EXAMPLE 9 [0034] The coating processes in examples 1-8 are repeated except that synthetic mica is used as the sheet-like substrates. EXAMPLE 10 [0035] Example 9 is repeated except that glass sheets are used as the sheet-like substrates. EXAMPLE 11 [0036] Example 9 is repeated except that aluminum oxide is used as the sheet-like substrates. EXAMPLE 12 [0037] Example 9 is repeated except that metal sheets made of Al, Cu, Ni and various alloys are used as the sheet-like substrates. EXAMPLE 13 [0038] Examples 1-12 are repeated except that the pH control agent MgO slurry is changed into Mg(OH) 2 slurry or a mixture of MgO slurry and Mg(OH) 2 slurry. EXAMPLE 14 [0039] Example 13 is repeated except that the pH control agent is calcium carbonate (CaCO 3 ) slurry or a mixture of CaCO 3 /MgO/Mg(OH) 2 at any ratio. APPLICATION EXAMPLES [0040] The pearlescent pigment prepared according to examples 1-14 is applied to the fields such as paints, coatings, printing ink, plastics, ceramic materials, leather coloration, wallpaper, powder coatings and cosmetics. For example, a coating with excellent color and luster can be prepared if the pearlescent pigment of the present invention is added to a paint or coating. Application Example 1 Using Paint Spraying as an Example [0041] 4.0 g of the pearlescent pigment is accurately weighed, 4.0 g of butyl acetate and 8.0 g of polyester automobile coating resin are added, dispersed for 10 min after stirring in a stirrer, and 84.0 g of automobile coating resin systems are further added, and stirred for 5 min. The viscosity of the coating is regulated to Ford 4# cup for 14-15s before spraying. A temperature of a spraying chamber is controlled at 25° C. and a relative humidity at 60% during spraying. With twice spray, a varnish is covered after flash drying for 10 min, and baked at 140° C. for 30 min after performing flash drying again. Application Example 2 Using Injection Molding as an Example [0042] 200 g of polypropylene (PP) materials are accurately weighed and dried at 105° C., put into a sealed plastic bag, added with 1 ml of gloss oil (or dispersed oil), then, shaken to sufficiently mix the gloss oil and the polypropylene materials. 4.000 g of the pearlescent powder is accurately weighed by using an analytical balance, put into the sealed plastic bag, shaken again, and rubbed to sufficiently evenly disperse the pearlescent powder into PP particles. [0043] After a temperature of a charging barrel reaches a set value (generally 180-200° C.), the prepared polypropylene materials are added into a hopper, and original remained materials in the charging barrel are extruded by virtue of rubber injection and rubber melting functions until new materials are extruded, wherein the extruded new materials need to have luster without impurities, dark spots, scorch or air bubbles, and meanwhile, nozzles are required to have no blocking phenomenon during rubber injection. Produced plastic sheets are stable and qualified products and automatic normal production can be carried out after front and back produced plastic sheets have no difference.
The present invention relates to a method for preparing pearlescent pigment through metal oxide coating based on a sheet-like substrate, and the obtained pearlescent pigment. The present invention further relates to a method for preparing pearlescent pigment through coating a sheet-like substrate by hydrolyzing metal salt under an acid condition, wherein a pH value is adjusted by using inorganics such as MgO, MgOH or CaCO 3 that does not dissolve in water but can dissolve through reacting with an acid. According to the method, no free metal oxide is generated when the metal salt is hydrolyzed, so that the production cost is reduced, product quality is improved, problems possibly generated in an application process of the product are avoided, and a production process is more environment-friendly.
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CROSS-REFERENCE TO RELATED APPLICATIONS This patent application is a continuation of U.S. patent application Ser. No. 14/494,525, filed Sep. 23, 2014, issued as U.S. Pat. No. 9,313,182 on Apr. 12, 2016, which is a continuation of U.S. patent application Ser. No. 13/439,827, filed Apr. 4, 2012, issued as U.S. Pat. No. 8,843,734 on Sep. 23, 2014, which claims the benefit of U.S. provisional application 61/471,682, filed Apr. 4, 2011. These applications are incorporated by reference along with all other references cited in this application. A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the paten disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. BACKGROUND OF THE INVENTION The present invention relates to the field of information or document management, and more specifically, to protecting documents at rest and in motion using declarative policies and encryption. Computers have evolved to become repositories for information from all aspects of life, including society's personal and business matters. These vast stores of knowledge are easily accessible through a variety of convenient methods, such as through a network connection. But as reliance on computers has grown, so has the need to keep information, particularly sensitive information, out of the hands of those who may abuse it. In the business realm, an information management system addresses this need to protect sensitive or high-value information. Some common business challenges that companies look to address are: (i) insider theft—protecting intellectual property from being stolen by personnel working within an organization (e.g., theft by employees, theft by contractors); (ii) external sharing—controlling intellectual property shared with partners or customers; (iii) confidentiality—preserving the confidentiality around sensitive or secret projects; and (iv) external collaboration—limiting third-party use of data. While these business challenges may seem straight forward, there are many operational or functional challenges associated with implementing an information management system. Some of these operational and functional challenges include classifying information, handling of different data types, controlling access to information, controlling use of information, making information available to users, protecting information at-rest, in-transit and in-distribution, and managing policies and information being managed. Therefore, there is a need for improved information management systems. BRIEF SUMMARY OF THE INVENTION A system allows enterprises to protect data after it leaves a server and protect data no matter where it goes. Using the system, companies can protect information or documents from: (i) insider theft; (ii) ensure confidentiality; and (iii) prevent data loss, while enabling collaboration both inside and outside of a company. An information management system can be used to enforce secure access (or otherwise restrict access) to the information of the system. The information management system can be a client-server arrangement, where files are stored on servers and client devices have a policy enforcer program resident on them. Each policy enforcer program evaluates rules and determines whether access to a file is permitted or not. Rules for the system can be managed at the server level, and then subsets deployed at the clients for evaluation by policy enforcer programs at each of the clients. A subset of the rules are stored at each client. The subset of rules at each client can be periodically refreshed, so that changes at the server level are propagated to each client. In an implementation, information of the system, such as files and documents, are stored in an unencrypted format. When unencrypted, despite the policy enforcers restricting access, the information can still be viewed by using appropriate techniques. For example, when the information is transmitted across a wire, a sniffer device can capture the bits being transmitted. A hard disk with unencrypted information and be removed and connected to a computer without a policy enforcer program. Then the information, which was previously restricted, can be accessed without any restrictions. In an implementation, information of the system is stored in an encrypted format. The data encryption and decryption are transparent to the user. At each client, in addition to the policy enforcer program, there is an encryption module, which handles encryption and decryption of the data. The system operates similarly as in the unencrypted system. However, after a policy enforcer allows access, the encryption module traps any information retrieval operation. When the information is encrypted, the encryption module handles decrypting the data. To decrypt the data, the encryption module requests a key from the policy enforcer program. To support its request, the encryption module provides trust information including a process identifier (e.g., MS Word process), file path, and user to the policy enforcer. With this trust information, the policy enforcer program can compare information about to previously allowed processes and determine whether to send key to the encryption module. If the information is not correct, the correct key is not sent, and the encryption module will not be able to unencrypt the information properly. If the trust information from the encryption module is correct, the policy enforcer program can send the key to the encryption module. The key can be stored locally on the device or may be a shared key, which is also stored at the server level. For example, the policy enforcer program can request the key from a key server of the information management system. In an implementation, a method includes: providing a document management system managing at least two documents where the document management system includes clients and servers; at a first client, executing a first policy enforcer program; at the first client, trapping by the first policy enforcer program a request by an e-mail application to send an e-mail with a document attachment, managed by the document management system, to a second client; at the first policy enforcer program, evaluating at least one policy associated with document attachment; as a result of the evaluating, determining that the send request is allowed, but before allowing to e-mail application to send the document attachment, encrypting the document attachment; and allowing to e-mail application to send the encrypted document attachment to the second client. The document attachment can be unencrypted. The at least one policy associated with document attachment can be stored at the first client. The document attachment is encrypted by an encryption module executing on the first client, the encryption module is separate from the policy enforcer program. In an implementation, a method includes: receiving a encrypted document attachment at a second client; detecting an attempt to open the encrypted document attachment at the second client at a second policy enforcer program at the second client; at the second policy enforcer program, evaluating at least one policy associated with encrypted document attachment; as a result of the evaluating, determining that the open operation is allowed; at an encryption module executing on the second client, determining the encrypted document attachment is encrypted; at an encryption module, attempting to obtain a key for the encrypted document attachment by sending a key request to the second policy enforcer program including information comprising a process identifier; at the second policy enforcer program, receiving the key request from the encryption module and evaluating the request based on the information comprising a process identifier; when the process identifier matches a previously saved process identifier, at the second policy enforcer program, sending a request to a key server of the document management system; after receiving a key from the key server at the second client, passing the key to the encryption module; and at the encryption module, using the received key in unencrypting of the encrypted document attachment to obtain the unencrypted document attachment. Other objects, features, and advantages of the present invention will become apparent upon consideration of the following detailed description and the accompanying drawings, in which like reference designations represent like features throughout the figures. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a simplified block diagram of a distributed computer network and clients. FIG. 2 shows a more detailed diagram of a computer system which may be a client or server. FIG. 3 shows a system block diagram of computer system. FIG. 4 shows a screen shot of a file in portable encryption data format having implicit Windows Explorer® file association. FIG. 5 shows a screen shot of a file in portable encryption data format having explicit Windows Explorer® file association. FIG. 6 shows a screenshot of a context menu entry for manually encrypting a file listed on Windows Explorer®. FIG. 7 shows a screenshot of a context menu entry for manually decrypting a file listed on Windows Explorer®. FIG. 8 shows a sample flow for automatically encrypting a file. FIG. 9 shows a sample flow for encrypting an email attachment. FIG. 10 shows a sample flow for switching encryption keys for e-mails. FIG. 11 shows a sample flow for switching encryption keys for file uploads. FIG. 12 shows a sample flow for converting file association using policy obligations. FIG. 13 shows a sample flow for automatically decrypting a file using policy obligation. DETAILED DESCRIPTION OF THE INVENTION FIG. 1 shows a simplified block diagram of a distributed computer network 100 incorporating an embodiment of the present invention. Computer network 100 includes a number of client systems 113 , 116 , and 119 , and a server system 122 coupled to a communication network 124 via a number of communication links 128 . Communication network 124 provides a mechanism for allowing the various components of distributed network 100 to communicate and exchange information with each other. Communication network 124 may itself be comprised of many interconnected computer systems and communication links. Communication links 128 may be hardwire links, optical links, satellite or other wireless communications links, wave propagation links, or any other mechanisms for communication of information. Various communication protocols may be used to facilitate communication between the various systems shown in FIG. 1 . These communication protocols may include TCP/IP, HTTP protocols, wireless application protocol (WAP), vendor-specific protocols, customized protocols, and others. While in one embodiment, communication network 124 is the Internet, in other embodiments, communication network 124 may be any suitable communication network including a local area network (LAN), a wide area network (WAN), a wireless network, a intranet, a private network, a public network, a switched network, and combinations of these, and the like. Distributed computer network 100 in FIG. 1 is merely illustrative of an embodiment incorporating the present invention and does not limit the scope of the invention as recited in the claims. One of ordinary skill in the art would recognize other variations, modifications, and alternatives. For example, more than one server system 122 may be connected to communication network 124 . As another example, a number of client systems 113 , 116 , and 119 may be coupled to communication network 124 via an access provider (not shown) or via some other server system. Client systems 113 , 116 , and 119 typically request information from a server computer system which provides the information. For this reason, servers typically have more computing and storage capacity than client systems. However, a particular computer system may act as both as a client or a server depending on whether the computer system is requesting or providing information. Additionally, although the invention has been described using a client-server environment, it should be apparent that the invention may also be embodied in a stand-alone computer system. Server 122 is responsible for receiving information requests from client systems 113 , 116 , and 119 , performing processing required to satisfy the requests, and for forwarding the results corresponding to the requests back to the requesting client system. The processing required to satisfy the request may be performed by server 122 or may alternatively be delegated to other servers connected to communication network 124 . Client systems 113 , 116 , and 119 enable users to access and query information stored by server system 122 . In a specific embodiment, a “web browser” application executing on a client system enables users to select, access, retrieve, or query information stored by server system 122 . Examples of web browsers include the Internet Explorer browser by Microsoft Corporation, the Firefox® browser by Mozilla Foundation, and others. FIG. 2 shows a more detailed diagram of a computer system which may be a client or server. FIG. 2 shows a computer system 201 that includes a monitor 203 , screen 205 , cabinet 207 , keyboard 209 , and mouse 211 . Mouse 211 may have one or more buttons such as mouse buttons 213 . Cabinet 207 houses familiar computer components, some of which are not shown, such as a processor, memory, mass storage devices 217 , and the like. Mass storage devices 217 may include mass disk drives, floppy disks, Iomega ZIP™ disks, USB removable storage, magnetic disks, fixed disks, hard disks, hard drives including both magnetic and flash storage in a single drive unit, CD-ROMs, recordable CDs, DVDs, DVD-R, DVD-RW, HD-DVD, Blu-ray DVD, flash and other nonvolatile solid-state storage, tape storage, reader, and other similar media, and combinations of these. A computer-implemented or computer-executable version of the invention may be embodied using, stored on, or associated with computer-readable medium. A computer-readable medium may include any medium that participates in providing instructions to one or more processors for execution. Such a medium may take many forms including, but not limited to, nonvolatile, volatile, and transmission media. Nonvolatile media includes, for example, flash memory, or optical or magnetic disks. Volatile media includes static or dynamic memory, such as cache memory or RAM. Transmission media includes coaxial cables, copper wire, fiber optic lines, and wires arranged in a bus. Transmission media can also take the form of electromagnetic, radio frequency, acoustic, or light waves, such as those generated during radio wave and infrared data communications. For example, a binary, machine-executable version, of the software of the present invention may be stored or reside in RAM or cache memory, or on mass storage device 217 . The source code of the software of the present invention may also be stored or reside on mass storage device 217 (e.g., hard disk, magnetic disk, tape, or CD-ROM). As a further example, code of the invention may be transmitted via wires, radio waves, or through a network such as the Internet. FIG. 3 shows a system block diagram of computer system 201 used to execute the software of the present invention. As in FIG. 2 , computer system 201 includes monitor 203 , keyboard 209 , and mass storage devices 217 . Computer system 201 further includes subsystems such as central processor 302 , system memory 304 , input/output (I/O) controller 306 , display adapter 308 , serial or universal serial bus (USB) port 312 , network interface 318 , and speaker 320 . The invention may also be used with computer systems with additional or fewer subsystems. For example, a computer system could include more than one processor 302 (i.e., a multiprocessor system) or a system may include a cache memory. The processor may be a multicore processor, such as the Intel Core 2 Duo, Intel Pentium® D, AMD Athlon™ 64 X2 Dual-Core, AMD Phenom™, or Microsoft Xbox 360 central processing unit (CPU). Arrows such as 322 represent the system bus architecture of computer system 201 . However, these arrows are illustrative of any interconnection scheme serving to link the subsystems. For example, speaker 320 could be connected to the other subsystems through a port or have an internal direct connection to central processor 302 . Computer system 201 shown in FIG. 2 is but an example of a computer system suitable for use with the present invention. Other configurations of subsystems suitable for use with the present invention will be readily apparent to one of ordinary skill in the art. Computer software products may be written in any of various suitable programming languages, such as C, C++, C#, Pascal, Fortran, Perl, Matlab (from MathWorks), SAS, SPSS, JavaScript, AJAX, and Java. The computer software product may be an independent application with data input and data display modules. Alternatively, the computer software products may be classes that may be instantiated as distributed objects. The computer software products may also be component software such as Java Beans (from Sun Microsystems) or Enterprise Java Beans (EJB from Sun Microsystems). An operating system for the system may be one of the Microsoft Windows® family of operating systems (e.g., Windows 95, 98, Me, Windows NT, Windows 2000, Windows XP, Windows Vista, Windows 7, Windows CE, Windows Mobile), Linux, UNIX, Sun OS, Ubuntu, or Macintosh OS X. Other operating systems may be used. Microsoft Windows is a trademark of Microsoft Corporation. Furthermore, the computer may be connected to a network and may interface to other computers using this network. For example, each computer in the network may perform part of the task of the many series of circuit simulation steps in parallel. Furthermore, the network may be an intranet, internet, or the Internet, among others. The network may be a wired network (e.g., using copper), telephone network (e.g., public switch telephone network or PSTN), packet network, an optical network (e.g., using optical fiber), or a wireless network, or any combination thereof. For example, data and other information may be passed between the computer and components (or steps) of a system of the invention using a wireless network using a protocol such as Wi-Fi (IEEE standards 802.11, 802.11a, 802.11b, 802.11e, 802.11g, 802.11i, and 802.11n, just to name a few examples). For example, signals from a computer may be transferred, at least in part, wirelessly to components or other computers. Information Management System An information management system employs a plurality of policies, a plurality of data protection clients and a plurality of encryption service modules to provide protection to information or documents. Information includes data in a relational database, in an enterprise resource planning (or “ERP”) system, in a product lifecycle management (or “PLM”) system, in a collaboration system such as Microsoft SharePoint®, on a Web server, and more. A document may exist in the form of a file on a file system, an attachment of an e-mail message, a file in an archive such as a zip file or Adobe Portfolio®, and more. U.S. provisional applications 60/755,019, filed Dec. 29, 2005, 61/357,016, filed Jun. 21, 2010, and 61/368,408, filed Jul. 28, 2010, and U.S. patent application Ser. No. 11/383,159, filed May 12, 2006, Ser. No. 11/383,161, filed May 12, 2006, and Ser. No. 11/383,164, filed May 12, 2006, and Ser. No. 11/615,477, filed Dec. 22, 2006, are also incorporated by reference. The plurality of policies that is used to control access to and use of information or documents may be defined independent of users, information, or documents. As such, a policy may be defined before a user who is affected by the policy is added to an information management system. Similarly, a policy may be defined before information or a document is created and access to the information or document is controlled by an information management system. Controlling access to information or documents includes allowing or denying the opening a file, renaming a file, deleting a file, opening a Web page, opening a document listing screen of a SAP client, and more. Controlling use of information or documents includes allowing or denying the copying content of a document, printing of a document, saving a document into a different file, copying a file, attaching a file to an email message, adding a file to an archive such as a zip file, embedded a file into a document, merging two documents, sending an email message to a recipient, uploading a file to a Web site, and more. The plurality of policies is stored in a policy server. Either the plurality of polices or a subset of the plurality of policies may be distributed to a data protection client from a policy server. The plurality of data protection clients control access to and use of information or documents by attaching to (or instrumenting) application programs that are used to access information or documents to intercept application program operations. When a data protection intercepts and application program operation, it sends the operation along with information relevant to the operation to a policy engine to perform policy evaluation. For an access or usage policy, a decision from policy evaluation includes allow or deny. In addition to policy decision, policy evaluation may return a policy obligation, optionally. Examples of an application program includes a word processor (e.g., Microsoft Word®, or Apple iWork Pages®), spreadsheet (e.g., Microsoft Excel® or Apple iWork Numbers®), presentation program (e.g., Microsoft PowerPoint®, Apple Keynote®), document viewer (e.g., Adobe Reader®), Web browser (e.g., Microsoft Internet Explorer®, Mozilla Firefox® or Apple Safari®), email client (e.g., Microsoft Outlook®), instant messenger (e.g., Microsoft Office Communicator® or Skype®), and more. Examples of application program operations includes opening a file, copy a file, moving a file, renaming a file, deleting a file, printing a document, copying content of a document, changing document classification, saving a document into a different file, uploading a file to a Web site, opening a Web page, showing a data page of an application (e.g., a component listing on a SAP client), sending an email message, attaching a file to an email, sending a message through instant messenger, inviting a user to join a video conference, capturing a screen image, and more. In additional to controlling access and usage of information or documents, a data protection client also controls access to encryption keys used by an encryption service module to encrypt and decrypt information or documents. The plurality of encryption service modules performs encryption and decryption on information or documents independent of application programs whereby encryption and decryption are transparent to the application programs. An encryption service module does not perform access control decision or enforcement on information or documents. All access control decisions and enforcement on information or documents are performed by a data protection client. Besides providing transparent encryption and decryption services, the plurality of encryption service modules also performs encryption key switching (also referred to as “key switching” in this document) on encrypted information or documents. Key switching is needed when access requirement to a particular encrypted information or document changes. For example, if a document is encrypted with encryption key A which is available only to a particular computing device and the document is being sent to recipient X who does not have access to the computing device, the document needs to be decrypted using encryption key A and re-encrypted with encryption key B which recipient X has access to. The process of decrypting particular information or document with a first encryption key and re-encrypting the particular information or document with a second encryption key is referred to as key switching in this document. Key switching may be used to make encrypted information or documents sharable among one or more users, or inversely not shared with any user. Key switching is also needed when encrypted information or documents shared among a first group of users needs to be shared with a second group of users. By switching from a first encryption key that is used to encrypt the information or documents to a second encryption key that is accessible by the second group of users, the information or documents becomes accessible by the second group of users after key switching is performed. Data Protection Client In an embodiment, a data protection client instruments an application program, intercepts an operation of the application program, evaluates a subset of policies according to the operation, information or a document being accessed (e.g., opening of file) or used (e.g., copy content of a document), and a user or user account operating the application program, enforces a decision (or an “effect”) from policy evaluation, and can implement zero or more policy obligations according to the subset of policies. A data protection client may instrument an application program using at least one of application plug-in, code injection, operating system management interface, operating system service provider, device driver, or any combination thereof. An example of an application plug-in includes Microsoft Word® add-in, Microsoft Excel® add-in, Microsoft PowerPoint® add-in, Microsoft Outlook® add-in, Microsoft Internet Explorer® add-in, Microsoft Windows Explorer® add-in, Adobe Reader® plug-in, Adobe Acrobat® plug-in, and more. An example of an operating system service provider is Microsoft WinSock Service Provider®. An operation of an application program (also referred to as “application program operation” in this document) includes an event or a notification generated in the application program, or a function invoked in the application program. An example of an application program operation includes opening of a file, copying content of a document, and more. For policy decision, an access or usage control policy decision is one of allow or deny. Policy decision for a monitoring policy is always allow. Other types of policies may support a different set of policy decisions. An example of enforcing an access policy decision includes allowing the opening a file, denying the opening a file, allowing the opening of a Web page, denying the display of a document list on a SAP client, and more. An example of enforcing an usage policy decision includes denying the copying content of a document, denying the sending an email message with a document attached, and more. A policy obligation is a task to be performed by a data protection client when a policy specifying the policy obligation is in the subset of policies being evaluated and invocation condition of the policy obligation is satisfied. A policy obligation is an optional element of a policy. A policy evaluation may not produce a policy obligation. An example of a policy obligation includes a log obligation that logs data to a central log server, an automatic tagging obligation that inserts one or more document attributes into a document, an interactive tagging obligation that queries a user to enter one or more document attributes and inserts the one or more document attributes into a document, a strip attachment obligation that removes an attachment from an email message, and more. A data protection client describes in this document implement functions of a policy enforcement point such as in U.S. patent application Ser. Nos. 11/383,159, 11/383,161, and 11/383,164, filed May 12, 2006, and Ser. No. 11/615,477, filed Dec. 22, 2006. A data protection client may also implement function of a policy decision point described in the same references. The role of a data protection client is to protect sensitive or high-value information or documents from unauthorized access or misuse. The types of information or documents a data protection client needs to protect and the environment it needs to operate under affects the implementation of a data protection client. For example, to protect a wide range of information or documents accessible from a desktop or laptop computer, a policy enforcer may be deployed. A policy enforcer is a module or other computer code, executing on a computer, that is used to protect information by controlling access to the information. Some examples of operations a policy enforcer controls are whether to allow: open operations (e.g., whether a user can open a document file with Microsoft Word), edit operation (e.g., whether a user can copy from one document into another document, whether a user can modify an e-mail's text), and many others. An example of a policy enforcer that can be used with this system is described in U.S. patent application Ser. No. 13/193,588, filed Jul. 28, 2011, and Ser. No. 11/615,477, filed Dec. 22, 2006, which are incorporated by reference. On the other hand, if the objective is to protect copying of high-value information or documents of a Microsoft Office® document or Adobe PDF® document, a lightweight enforcer described below may be deployed. In the case where sensitive information or documents are accessed only from a Web browser and the users are outside of an organization, an on-demand enforcer described below may be employed. Further, if the objective is to distribute information or documents to users outside of an organization, a rights managed container described below may be employed. In additional to employing a data protection client described here, an encryption service module may be employed to protect data at rest or in distribution. More details on data-at-rest and data-in-distribution are described further below in this document. Lightweight Enforcer In another implementation, a data protection client is a lightweight enforcer. A lightweight enforcer is simple to deploy and it may be deployed without an installation step. A lightweight enforcer is designed to provide targeted data protection functionalities. An example of targeted data protection functionalities is controlling access to and use of Microsoft Office® documents while a document is opened with or in Microsoft Word®, Microsoft Excel® or Microsoft PowerPoint®. Another example of targeted data protection functionalities is to prevent a user from saving sensitive or high-value information or documents to local disk or enforcing encryption of such information or documents before it is saved to local disk. Another example of targeted data protection functionalities is to audit all information or documents access by a user and save audit log data on local host or to a remote server. Since a lightweight enforcer is simple to deploy, it may be deployed on an unmanaged computing devices (i.e. computing devices not managed by an information management system) use to access protected information or documents. When deployed on an unmanaged computing device, a lightweight enforcer may deny access to information or documents managed by the information management system by default. A user is allowed access to information or a document only if it is explicitly allowed by a policy. The exclude-by-default function may be implemented using one or more policies or by configuration to a lightweight enforcer. A lightweight enforcer communicates with a policy server periodically. A lightweight enforcer obtains policies relevant to the lightweight enforcer from a policy server. A lightweight enforcer also communicates with a log server (or a “report server”) and sends audit log data to the log server. To enforce policies on a computing device, a lightweight enforcer instruments an application program on the computing device, intercepts an operation of the application program, effects policy evaluation on the operation, implementing a decision from policy evaluation, and optionally invokes a policy obligation. To provide persistent protection to information or documents or protect information or documents in-transit or in-distribution, an encryption service module may be employed. When an encryption service module is deployed on a computing device with a lightweight enforcer, the lightweight enforcer will provide encryption key management service to an encryption service module. The encryption key management service includes encryption key generation, encryption key lookup with an encryption key management server, encryption key caching, encryption key expiration, and more. On-Demand Enforcer In another implementation, a data protection client is an on-demand enforcer. An on-demand enforcer may be a client application program, application program plug-in (e.g., a Microsoft Internet Explorer add-in) or application extension (e.g., a Web browser toolbar) that is downloaded to a computer device and run in a Web browser process. Since an on-demand enforcer runs in a Web browser process, it may only enforce policies applicable to a Web browser. Example use control policies for Web browser includes denying the copying of content of sensitive information or a document opened in a Web browser, denying saving of a high-value document opened in a Web browser, placing a security overlay on information or a document opened in a Web browser, and more. A security overlay is a security measure similar to print watermark that is overlay on top of content. Security overlay is a policy obligation. An on-demand enforcer may be installed on an unmanaged computing device to enable access to information or documents protected by an information management system. Typically, a user downloads an on-demand enforcer when the user needs to access information of a document protected by the information management system. After an on-demand enforcer is downloaded, it is installed into one or more Web browser on a computing device. To enforce policies on a Web browser, an on-demand enforcer instruments the Web browser, intercepts an operation of the Web browser, effects policy evaluation on the operation, implementing a decision from policy evaluation, and optionally invokes a policy obligation. An on-demand enforcer may deny access to information or documents managed by the information management system by default. In this case, a user is allowed access to information or a document only if it is explicitly allowed by a policy. The exclude-by-default function may be implemented using one or more policies or by configuration to an on-demand enforcer. An on-demand enforcer may be packaged with a predefined set of policies and user identities. An on-demand enforcer may also communicate with a policy server periodically to obtain updated policies and user identities. An on-demand enforcer may also communicate with a log server and send audit log data to the log server. To provide persistent protection to information or documents or protect information or documents in-transit or in-distribution, an encryption service module may be employed. When an encryption service module is deployed with an on-demand enforcer, the on-demand enforcer provides encryption key management service to the encryption service module. The encryption key management service includes encryption key generation, encryption key lookup with an encryption key management server, encryption key caching, encryption key expiration, and more. Rights Managed Container In another implementation, a data protection client is a rights managed container. A rights managed container is an executable information or document archive (also referred to as “executable archive”) with built-in data protection client and encryption service module. In other words, a rights managed container comprises a data protection client, an encryption service module and a plurality of encrypted information or documents. Examples of an executable archive include an executable (.exe) file on Windows® operating system, an executable binary file on Apple OS/X® or Linux® operating system, and more. To view information or documents in a rights managed container, a user invokes an executable archive using a method for starting an application program on an operating system of a computing device. The executable archive starts by acquiring the identity of a user attempting to access the information or documents in the executable archive. The executable archive may obtain a user's identify by querying the operating system it is running on, or it may query the user to login. Once the user is authenticate, the executable archive presents one or more lists of information or documents to the user. The executable archive may filter out information or documents the user is not allowed to access, optionally. The user may select particular information or document in a list for viewing. The executable archive invokes an application program installed on the computing device to display the particular information or open the particular document. A policy enforcement client in the executable archive instruments the application program to control usage of the particular information or document. The policy enforcement client establishes trust with the application program whereby allowing encryption key to be provided to an encryption service module on behave of the application program. Since the particular information or document in the executable archive is encrypted, an encryption service module in the executable archive is invoked to decrypt the information or document whereas providing a transparent decryption service to the application program. Implementations of a data protection client are not limited to those described above. These implementations are only meant to be illustrative of examples of data protection clients that can be used by the system. Roles of Encryption Service Module An encryption service module is an add-on to a data protection client. An encryption service module provides transparent encryption and decryption services to application programs and encryption key switching to data protection client. An encryption service module it does not perform access or use control on information or documents. It also does not manage encryption keys. The transparent encryption and decryption services are operating system services as such transparent encryption and decryption services do not run in an application program process space. Unlike application program-based encryption solution (e.g., Adobe Reader®, Microsoft Word®, or Microsoft Excel®) where decrypted data is provided only to an application program, transparent encryption and decryption services encrypt and decrypt data for all trusted application programs on a computing device. In addition, transparent encryption and decryption services are file format agnostics. Files of any format may be encrypted into a portable encrypted file. On the contrary, many application program-based encryption solutions (e.g., Adobe Reader®, Microsoft Word®, or Microsoft Excel®) has file format dependency. Further, application program-based encryption solutions provides limited use control (e.g., Adobe Reader® cannot protect screen capture) and it cannot protect content copied outside of the application program. While different from application program-based encryption solution, transparent encryption and decryption services shares some common features with encrypted file system (e.g., Microsoft NTFS). Both transparent encryption and decryption services and encrypted file system operate as operating system services. Both transparent encryption and decryption services and encrypted file system are transparent to application programs. However, while transparent encryption and decryption services allow an encrypted file to be shared with other users, a file encrypted using NTFS® implementation of encrypted file system allows only the user who encrypt the file or a recovery agent to access the encrypted file. Transparent encryption and decryption services allow copying a file from a first file system to a second file system without decrypting content of the file. On the other hand, NTFS® implementation of encrypted file system decrypts content of an encrypted file when the encrypted file is copied from a NTFS® file system to a Microsoft FAT® file system. Also, when an encrypted file on NTFS file system is attached to an email message, the attached file is decrypted. Transparent encryption and decryption services attached an encrypted file to an email message. A data protection client releases an encryption key to encryption service modules only if the application program that accesses particular encrypted information or a document is deemed trusted. To establish trust on an application program, a data protection client requires that an application program be instrumented by the data protection client and the data protection client has intercepted an open operation on particular encrypted information or document by a particular user within a period of time and the data protection client has decided to allow the application program to open the particular encrypted information or document. When an application program is entrusted to access particular encrypted information or document, it is referred to as a trusted application program for the particular encrypted information or document. While an application program may be trusted by a data protection client to access particular information or document, it may not be trusted to access another information or document. A data protection client may keep trusted process information for a period of time. As a result, an application program instance may access unencrypted data during the period of time. To ensure data is protected while unencrypted, an encryption service module only provides decrypted data of particular information or document to an application program instance that is trusted by a data protection client. Before an encryption service module encrypts or decrypts particular information or document, it requests an encryption key for the particular information or document from a data protection client providing at least an encryption key identifier and a process identifier of the application program instance that attempts to access the particular information or document in the request. The data protection client returns the encryption key associates with the key identifier if the application program instance is trusted. In an implementation, an encryption service module uses an open-cipher based encryption algorithm such as advanced encryption standard (AES), data encryption standard (DES), skipjack, blowfish, or other ciphers. The module is used to encrypt information or documents and data encryption key. In other implementations, an encryption service module uses proprietary ciphers. Transparent Decryption In an embodiment, an encryption service module intercepts a read operation of an application program instance on a file on a file system. If an encryption flag on the file is set, the encryption service module obtains an encryption key matching the encryption key identifier associated with the file to decrypt data requested by the read operation. The decrypted data is returned in the read operation of the application program instance. In effect, decryption is transparent to the application program instance. The application program instance operates while unaware of the file is being encrypted, and a decryption operation is performed by the encryption service module to service its read operation. If an encryption flag on the file is not set, the encryption service module treats the read operation as a pass-through and allows the native read operation to execute to completion. A native read operation is a read operation executed by an application program when an encryption service module is not installed. To obtain an encryption key matching the encryption key identifier associated with the file, an encryption service module locates and encryption key in its encryption key cache using an encryption key identifier, process identifier of an application program instance, and the path to the file. An encryption key is retrieved from the encryption key cache if one is found. If an encryption key cache does not contain a matching encryption key, the encryption service module requests an encryption key from a data protection client. The encryption service module provides at least an encryption key identifier associated with the file, a path to the file, and a process identifier of the application program instance to the data protection client. If the data protection client determines the application program instance is to be trusted with the file (i.e., the data protection client allowed the application program instance to access the file recently), the data protection client returns an encryption key matching the encryption key identifier to the encryption service module. The encryption key returned by the data protection client may come from its encryption key cache, or may be obtained from an encryption key management server. If the data protection client determines the application program instance is not to be trusted with the file, the data protection client returns an untrusted status to the encryption service module. The encryption service module treats an untrusted request as a pass-through. As a result, the read operation returns encrypted data (or raw data from the encrypted file). If an encryption key matching the encryption key identifier is not found, a data protection client returns an error to the encryption service module. The encryption service module returns an error to the read operation. If a read error is handled by the application program instance, a user may be presented with a human readable error message indicating the application program instance has failed to read from the file. Transparent Encryption In an embodiment, an encryption service module intercepts a write operation of an application program instance on a file on a file system. If an encryption flag on the file is set, the encryption service module obtains an encryption key matching the encryption key identifier associated with the file to encrypt data passed in the write operation. The encrypted data is written to the file. In effect, encryption is transparent to the application program instance. The application program instance operates while unaware of the file is being encrypted, and an encryption operation is performed by the encryption service module to service its write operation. If an encryption flag on the file is not set, the encryption service module treats the write operation as a pass-through and allows the native write operation to execute to completion. A native write operation is a write operation executed by an application program when an encryption service module is not installed. To obtain an encryption key matching the encryption key identifier associated with the file, an encryption service module locates and encryption key in its encryption key cache using an encryption key identifier, process identifier of an application program instance, and the path to the file. An encryption key is retrieved from the encryption key cache if one is found. If an encryption key cache does not contain a matching encryption key, the encryption service module requests an encryption key from a data protection client. The encryption service module provides at least an encryption key identifier associated with the file, a path to the file, and a process identifier of the application program instance to the data protection client. If the data protection client determines the application program instance is to be trusted with the file (i.e., the data protection client allowed the application program instance to access the file recently), the data protection client returns an encryption key matching the encryption key identifier to the encryption service module. The encryption key returned by the data protection client may come from its encryption key cache, or may be obtained from an encryption key management server. If the data protection client determines the application program instance is not to be trusted with the file, the data protection client returns an untrusted status to the encryption service module. The encryption service module treats an untrusted write operation as an error. If an encryption key matching the encryption key identifier is not found, a data protection client returns an error to the encryption service module. The encryption service module returns an error to the write operation. If a write error is handled by the application program instance, a user may be presented with a human readable error message indicating the application program instance has failed to write to the file. In an example, data level encryption transparency is realized with a data protection client and an encryption service module. An application program attempts to open an encrypted file, a data protection client intercepts the open operation and send the open operation along with information associated with the open operation to a policy engine. The policy engine evaluates a set of relevant policies to determine if a user is allowed to open the encrypted file. If the user is not allowed to open the encrypted file, the data protection client denies the open operation. This means the application program does not have access to unencrypted data from the encrypted file. If the user is allowed to open the encrypted file, the data protection client allows the native open operation (i.e., the code that is being run if data protection code is not installed) to run to completion. At the same time, the policy engine caches trust information associate with the open operation. The trust information includes, process identifier of the application program instance that made the file open requested, the encrypted file path and the user involved in the file open request. After the application program instance completes the file open operation successfully, it starts reading from the encrypted file. The encryption service module intercepts read and write operations, on a first read operation, encryption service module needs to obtain a key from data protection client to decrypt file content. When encryption service module requests an encryption key from the data protection client, it provides the process identifier of the application program instance, the encrypted file path, and optionally the user information (if data protection client does not have it already). If data protection client determines the application program instance may be trusted with the encrypted file, an encryption key is returned to encryption and service module. The encryption key may be a local key or shared key. The encryption key will be used to decrypt the data requested in the read operation and subsequence I/O requests. If data protection client determines the application program instance may not be trusted with the encrypted file, no encryption key is return. The encryption service module is notified by the data protection client that the application program instance is not to be trusted. In this case, encryption service module allows the native read operation code to be executed and raw encrypted data is returned to an application program. Throughout this process, neither the user nor the application program is aware of the encryption key request and decryption took place in the background. The data protection client and the encryption service module together archived data level encryption transparency. Encryption Key Switching A local encryption key (also referred to as “local key” in this document) is an encryption key available only to a first computer. Information or documents encrypted using a local key will not be accessible on a second computer because local key exist only on the first computer and it is not distributed to other computers. In order to make encrypted information or document portable, information or a document must be encrypted using a shared encryption key (also referred to as “shared key” in this document). A share key is typically generated by a encryption key management server and may be obtained by first or second computer when needed to decrypt encrypted information or document. In an embodiment, an encryption service module performs encryption key switching (or “key switching”) on encrypted information or documents. Key switching describes a process of decrypting a data encryption key (or “data key”) using a first encryption key that is used to encrypt particular information or document and re-encrypting the data key with a second encryption key whereby making the particular information or document accessible only with second encryption key after the switching is completed. During the entire key switching process, the particular information or document is never decrypted. Only the data key that is used to encrypt the particular information or document is decrypted and re-encrypted. Key switching is effective since the length of a data key is short. The computation cost to decrypt and encrypt a data key is low. Key switching can be applied to stop sharing particular information or document. An encryption service module may facilitate switching an encryption key in the particular information or document from a shared key to a local key. Inversely, switching a local key to a shared key makes particular information or document sharable. Key switching may be performed automatically or according to a policy. Data-at-rest, Data-in-motion, and Data-in-distribution A data protection client protects information or documents in place (or “data-at-rest”) from unauthorized access. There are situations that a data protection client cannot protect information or documents. First, when information or documents is physically removed from a computing device (e.g., removing a hard disk from a laptop computer), the information or documents that was protected by a data protection client becomes unprotected. Second, when information or documents is being sent from a first computing device to a second computing device (or “data-in-motion”), unless the transport provides end-to-end encryption, the information or documents is not protected. Third, when information or documents is sent to a recipient list via email messages, the copies of information or documents sent in email messages are no longer protected even after they arrived at their destinations (i.e., data-in-distribution). Data-at-rest refers to information or documents stored temporary or permanently on a storage device. Examples of a storage device include volatile memory, hard disk, CD-ROM, DVD-ROM, Flash drive, Flash card, tape, and more. Data-in-motion refers to content of information or documents being transmitted via a transport and has not reached its destination. Examples of data-in-motion include: (a) an e-mail message that is en route to a recipient's mailbox; (b) a file being transferred using file transfer protocol (or “FTP”); (c) a file or a webpage being downloaded from a Web server (e.g., using HTTP protocol); (d) a message or a file being sent using an instant messaging program; and more. Data-in-distribution refers to information or documents being copied and copies of the information or documents reside outside the realm managed by an information management system. Examples of data-in-distribution include: (a) a file is attached to an email message and sent to a mailing list outside of an organization; (b) a file is uploaded to a public Web site; (c) a file is copied to a USB device and the USB device is removed from a computer; (d) content of a document is copied to a chat room or an instant messenger; and more. In order to provide persistent protection to information or documents no matter the information or document is at rest, in motion or in distribution, the information or documents should be encrypted. By encrypting particular information or documents, the particular information or documents may not be accessed unless data protection client and encryption service module are available. An encryption service module compliments a data protection client by extending information or document protection from data-at-rest under management of an information management system to all of data-at-rest, data-in-motion and data-in-distribution. Encryption Key Management Server In an embodiment, an encryption key management server provides a mechanism to share encryption keys used to encrypt information or documents in an information management system. An encryption key management server provides a repository for storing shared encryption keys (or “shared keys”), generates new shared keys, and provides shared keys to a data protection client. A data protection client may request a shared key by key ring identifier or key identifier. When a data protection client requests a new shared key from an encryption key management server to encrypt particular information or documents, it needs to request a shared key by key ring identifier. If the key ring identifier matches a shared key ring, the key encryption management server returns the shared key ring to the data protection client. The request is made by a key ring identifier because the data protection module does not know the key identifier of the shared key to be used to encrypt information or a document at this time (i.e., the newest key in a shared key ring is used to encrypt information or a document). To decrypt particular information or document encrypted with a shared key, a data protection client needs to provide a key identifier of the shared key in a request to an encryption key management server. If the key identifier matches a shared key in a shared key ring, the shared key ring is is returned to the data protection client. A key ring holds one or more shared keys. The newest shared key in a key ring is made the default key and an encryption service module uses the default key to encrypt data. The remaining shared keys in the key ring are used to decrypt data. Older shared keys are not used to encrypt data. An encryption key management server manages one or more key rings. In order to support a large number of data protection clients, a key management server may be deployed using one of the following topologies: standalone, master-slave, cluster or federation. In an implementation, an encryption key management service of a data protection client manages encryption keys on a computing device where encryption and decryption are performed. An encryption key management service manages shared key rings it obtained from an encryption key management server. It also manages a local key ring it creates. A key ring is identified by a unique key ring identifier. A shared key ring is assigned a unique key ring identifier by an encryption key management server. Whereas, a local key is assigned a predefined identifier by an encryption key management service. The encryption key management service caches a shared key ring for a period of time (e.g., one hour, one day, 3 days, one week, and more). The encryption key management service also communicates with the encryption key management server periodically to updates cached shared key rings. Encryption key management server adds new shared key to a shared key ring periodically to minimize data loss resulted from compromised encryption key. Encryption keys in a local key ring are generated by an encryption key management service. An encryption key management service also generates an encryption key periodically and places it in a local key ring. A key ring identifier comprises any one of an integer, a string, or an object. A key identifier comprises any one of an integer, a string, or an object. While encryption key management on a computing device is performed by an encryption key management service of a data protection client, encryption and decryption are performed by an encryption service module. An encryption service module communicates with an encryption key management service to obtain an encryption key to be used in encrypting or decrypting information or documents. The encryption service module may perform encryption or decryption using a local key or a shared key. Only an encryption key in a key ring (not a key ring) is provided to an encryption service module by an encryption key management service. Portable Encryption Data Format In an embodiment, encrypted information or a document is stored in a portable encryption data format (also referred to as “PED format” in this document). A portable method means that the system retains its ability to protect information, even across different technical boundaries. Some boundaries are differences in operating systems, device types with different capabilities, or different applications. PED format consists of at least three sections: header, metadata and encrypted data. The header section contains at least an encryption key identifier (or “key identifier”) and a data encryption key (or “data key”). Optionally, the header section may also contain any of an unencrypt allowed flag, a data key encryption algorithm, a data encryption algorithm, an original name, a creation time and a last modified time. The metadata section contains at least one information or document attribute (also referred to as “PED attribute”). The encrypted data section contains encrypted rendition of the unencrypted information or document. A key identifier is a unique identifier for indentifying an encryption key used to encrypt a data key stored in the header. Typically, a key identifier is generated by an encryption key management server or an encryption key management service of a data protection client. A key identifier may identify a local key or a shared key. A key identifier may be an integer, a string or an object. A data key is an encryption key used to encrypt information or a document in the encrypted data section. It may be used encrypt PED attributes in the metadata section, optionally. A data key is typically generated by an encryption service module. While a data key is not guaranteed to be unique, data keys are generally different between two PED format files. An unencrypt allowed flag is a directive to encryption service module indicating if the PED file should be decrypted by a policy obligation. If unencrypt allowed is set, a policy obligation may decrypt the PED file. If unencrypt allowed is not set (or is not present), a policy obligation can only perform key switching, modify PED file name to make encryption implicit or explicit, or both. To support different encryption algorithms, a data key encryption algorithm may specify the encryption algorithm used to encrypt a data key, a data encryption algorithm may specify the encryption algorithm used to encrypt the unencrypted information or document. Original name, creation time and last modified time are recorded in the header to facilitate transparent decryption of a file. By recording file attributes from an unencrypted file, an application program that access a PED file will be presented with unencrypted (or original) file attributes by an encryption service module. In the case where information or a document represents a file, an original name is the name of the file being encrypted. Creation time and last modified time are the corresponding file attributes of the file. In an implementation of the portable encryption data format, original name, creation time and last modified time are stored in the metadata section. The metadata section stores PED attributes. Examples of PED attributes include: file attributes (e.g., file owner) from unencrypted information or document, document properties (e.g., author, title or revision) from unencrypted information or document, document classification (e.g., confidential, or company secret), lineage (i.e., where does this information or document come from?) and more. PED attributes are stored as a collection of (name, value) pairs. PED attributes may be stored encrypted or unencrypted. When PED attributes are encrypted, they may be encrypted using the data key, a local key, a shared key, a metadata encryption key, or any combination thereof. An information manage system may use a common metadata encryption key to encrypt PEP attributes. The encrypted data section contains encrypted rendition of the unencrypted information or document. Data in the encrypted data section is encrypted using a data key stored in the header. Encrypted data section may contain data encrypted using any standard-based or non-standard-based encryption algorithm. Data in PED format may be stored in a file or transmitted in a data stream. A file in PED format is referred to as a PED file in this document. A data stream containing data in PED format is referred to as PED stream in this document. A data protection client may access information or document attributes in metadata section of a PED file for the purpose of policy evaluation. If metadata section of a PED file is encrypted, a data protection client may request unencrypted information or document attributes from an encryption service module which has the ability to decrypt metadata. A file tagging policy obligation may read and write metadata section of a PED file. If metadata section of a PED file is encrypted, a file tagging policy obligation may request an encryption service to read information or document attributes form, and write information or document attributes to metadata section of a PED file. While encrypting information or a document, an encryption service module copies information or document attributes associated with unencrypted information or document to metadata section of a resulting PED file. Similarly, while decrypting a PED file, an encryption service module copies information and document attributes in metadata section of the PED file to a resulting unencrypted information or document. Microsoft Windows and File Extension File association is a feature in Microsoft Windows®. File association allows associating an application program to an action applied to a file of a particular type. In Microsoft Windows®, a file type is defined based on a file extension (e.g., .docx or .pdf). An action that may be applied to a file includes open, edit, explorer, print, and more. If an application program is associated with the open action of a file extension, the application program will be invoked when a user double click on a file listed on Windows Explorer®. There are other methods to open a file with a default application program with file association. For example, right click on a file on Windows Explorer® to show a context menu and select Open menu entry from the context menu. Another example is entering a file name (including file extension) into a command window (e.g., DOS Prompt®). In Microsoft Windows® environment, file association of a PED file may be implicit or explicit. When file association is implicit, a PED file will have the same file name as the unencrypted file. As a result, the same application program that is invoked to open an unencrypted file through file association will continue to open the PED file which is a rendition of the unencrypted file. When file association is explicit, a PED file will be assigned a new file extension (e.g., .nxl). Typically, a file extension register to PED file is appended to the file name of the unencrypted file. With explicit file association, a PED file cannot be opened by the application program associated with the file extension of the unencrypted file. In an embodiment, implicit file association is applied with encryption. By applying implicit file association, encryption is transparent to users and application programs when data protect client and encryption service module are presence. In an example, a first file is encrypted to produce a second file. The first file is an unencrypted file with a first file name (e.g., foo.doc). The second file is a PED file with a second file name (e.g., foo.doc). To make encryption transparent to application programs used to open the second file on Microsoft Windows®, an encryption operation preserves the first file name whereby making the second file name the same as the first file name. By preserving the first file name, Microsoft Windows® file association remains unchanged on the second file. When the second file is opened through file association (e.g., double clicking on the file on Windows Explorer), the application program associates with the second file will be launched. When the application program attempts to open the second file, a data protection client intercepts the open operation and performs policy evaluation. If a user is allowed to open the second file using the application program, the application program instance that attempts to open the second file will become trusted. When the application program instance attempts to read data from the second file, the read operation is intercepted by an encryption service module. The encryption service module communicates with the data protection client to obtain an encryption key with the key identifier in the second file. The data protection client returns an encryption key to the encryption service module because the application program instance is trusted on the second file. The encryption service module decrypt the data requested by the read operation and returns the decrypted data to complete the read operation. In the process of opening the second file with the application program, neither the user nor the application program needs to be aware of the second file being encrypted. There is also no special action taken by the user or the application program to access the second file which is encrypted. In an implementation, an encryption service module encrypts and decrypts file on a computing device using a local key. A file encrypted by the encryption service module is thus accessible only on the computing device. In an implementation, an encryption service module retains the file name of a file when it encrypts a file on a computing device. The original unencrypted file is replaced with an encrypted file. The encrypted file may be opened from Windows Explorer® just like the original unencrypted file, no special user action is required. In an implementation, an encryption service module replaces an icon associated with a PED file shown on Windows Explorer® with an icon that indicates the file is encrypted. Referring to FIG. 4 , in an implementation, an encryption service module overlay an icon associated with a PED file 401 shown on Windows Explorer® with an icon that indicates the file is encrypted. The combined icon provides a visual cue illustrating both original unencrypted file type and encryption status. For example, icon 402 of file “foo2.doc” shows a document icon, used by the operating system to identify a document file. At the lower left of the icon, is overlaid a smaller icon, showing that the file is encrypted. In an embodiment, explicit file association is applied with encryption. By applying explicit file association, a PED file may be shared with or distributed to a computer that does not have a data protection client and an encryption service module installed. In an example, a first file is encrypted to produce a second file. The first file is an unencrypted file with a first file name (e.g., foo.doc). The second file is a PED file with a second file name (e.g., foo.doc.nxl). The second file name is constructed by appending a new file extension (e.g., .nxl for NextLabs Portable Encrypted File) to the first file name. By providing a new file extension to the second file name, Microsoft Windows® file association is not preserved. While preserving file name when encrypting a file helps make encryption transparent on a computer that has a data protection client and an encryption service module installed. When an encrypted file with preserved file name is placed on a computer without a data protection client and an encryption service module installed, opening the encrypted file through file association will result in an error. To avoid such problem, it is advantageous to assign a special file extension to an encrypted file to denote its being a PED file. Referring to FIG. 5 , in an implementation, installing encryption service module includes registering a PED file extension (e.g., .nxl). Registering PED file extension also includes associating the file extension with a PED file icon 501 and PED file type 502 . Manual Wrapping and Unwrapping In an embodiment, a user may encrypt or decrypt a file using a context menu on Windows Explorer®. A user may also use the context menu to switch encryption key on a PED file. Referring to FIG. 6 , in an implementation, a Window Explorer® shows a context menu with an encrypt menu entry 601 designated by the “Wrap” option when a user select an unencrypted file. This context menu can be reached by using the right-click button of the user's mouse. The context menu provides additional encryption options including: (a) encrypt a file using a local key or a shared key; (b) make the resulting PED file implicit or explicit; (c) remove the file after encryption is completed; or (d) save the resulting PED file to a different location. Other implementations of the system allows a user to encrypt files using the system using other methods. For example, the system can use a dedicated icon on the Windows Explorer toolbar to encrypt files selected by the user. In another example, the user can encrypt files using the system by dragging files from the Windows Explorer to a designated area of the screen (e.g., to another icon, to an open window, or other method) to select which files to encrypt. Referring to FIG. 7 , in an implementation, a Windows Explorer® shows a context menu with a decrypt and a sharing menu entry 701 when a user select a PED file. A user may select the decrypt menu entry to decrypt a PED file. A user may select the sharing menu entry to select an encryption key. The encryption key may be a local key or a shared key. In an embodiment, a user may encrypt a file by copying or moving the file into a directory flagged for auto-encryption. A directory may be flagged for auto-encryption with an encryption service module. The encryption service module intercepts file operations (e.g., create file, copy file or move file) on a directory flagged for auto-encryption and encrypts a file when the file is created in the directory or after the file is written to the directory. A user may copy or move a file into a directory flagged for auto-encryption using drag-and-drop, clipboard or command line function of Microsoft Windows®. In an implementation, to intercept file operations of a directory flagged for auto-encryption, an encryption service module may maintain a list of directory it monitors. Auto Wrapping and Unwrapping In an embodiment, a data protection client and an encryption service module corporate to perform automatic encryption of an unencrypted file when the unencrypted file is copied to a shared location, copied to a removable device, uploaded to a public server, or sent in an email as an attachment. Automatic encryption may be a function of a data protection client, or it may be a function of a policy (e.g., implemented by an autowrap policy obligation). In an example, User A of design department logs on to a computer with policy enforcer and encryption service module installed. User A copies a confidential document c:\docs\foo.doc to a file server outside the design department \\inter-depart\share\john\review for User B to review. In the policy enforcer, a policy specifies that when a confidential document is copied to a file server outside the department, the confidential document will be encrypted automatically. The policy is: FOR document.class=confidential ON COPY TO \\inter-dept\share\** OR \\public\share\** BY user=design-department DO ALLOW ON ALLOW INVOKE Auto-Encrypt FIG. 8 shows a flow 801 for automatically encrypting a file using policy obligation when the file is copied to a non-department file server. In step 802 , User A copies a file c:\docs\foo.doc to \\inter-depart\share\john\review. In step 803 , a policy enforcer intercepts the file copy operation. In step 804 , the policy enforcer sends information regarding the file copy operation to a policy engine for evaluation. In step 805 , the policy engine selects a subset of policies relevant to the file copy operation which includes the above policy. In step 806 , the policy engine evaluates the select subset of policies. In step 807 , the policy engine determines if the file copy operation should be allowed. In step 808 , the file copy operation is allowed and policy obligation is auto-encrypt. The policy enforcer invokes an auto-encrypt policy obligation with source file path (i.e., c:\docs\foo.doc) from the file copy operation and the destination file path (i.e., \\inter-depart\share\john\review\foo.doc.nxl) constructed by append .nxl file extension to destination file path of the file copy operation. In step 809 , the auto-encrypt policy obligation calls encryption service module with the source and destination file path to create an encrypted file at the destination. In step 810 , file copy operation is completed with an encrypted file at the destination (i.e., \\inter-depart\share†john\review\foo.doc.nxl). In step 811 , file copy operation is denied. The policy enforcer blocks the file copy operation. In step 812 , file copy operation ends. In an example, a user of Company A logs on to a computer with policy enforcer and encryption service module installed. The user attaches a design drawing file to an email message and sends the email message to a recipient of Company B. A policy enforced by the policy enforcer specifies that all engineering drawing files send to a recipient outside the company will be encrypted automatically. The policy is: FOR email.attach=*.dwg ON SEND TO *@CompanyB.com BY user=* DO ALLOW ON ALLOW INVOKE Auto-Encrypt(ShareKey=SK_CompanyB) FIG. 9 shows a flow 901 for encrypting an email attachment with a shared key using policy obligation. In step 902 , a user sends an email message with an engineering drawing magic.dwg attached. In step 903 , a policy enforcer intercepts the send operation. In step 904 , the policy enforcer sends information regarding the send operation including information on email attachment magic.dwg to a policy engine for evaluation. In step 905 , the policy engine selects a subset of policies relevant to the send operation and email attachment which includes the above policy. In step 906 , the policy engine evaluates the select subset of policies. In step 907 , the policy engine determines if the send operation should be allowed. In step 908 , the send operation is allowed and policy obligation is auto-encrypt. The policy enforcer extracts an email attachment magic.dwg into a temporary file. In step 909 , the policy enforcer invokes an auto-encrypt policy obligation on temporary file with shared key ring identifier SK_CompanyB and constructed an encrypted file name (i.e., magic.dwg.nxl) by append .nxl file extension to the email attachment file name. In step 910 , the auto-encrypt policy obligation calls encryption service module with the temporary file as source path, a destination file path and a shared key ring identifier SK_CompanyB to create an encrypted file. In step 911 , the policy enforcer reattaches the encrypted file to the email message using the encrypted file name (magic.dwg.nxl). In step 912 , the send operation completes successfully and the email message is sent. In step 913 , the send operation is denied. The policy enforcer blocks the send operation. In step 914 , the send operation ends. In an embodiment, a data protection client and an encryption service module corporate to perform automatic key switching on a PED file when the PED file is copied to a shared location, copied to a removable device, uploaded to a public server, or sent in an email as an attachment. Automatic key switching may be a function of a data protection client, or it may be a function of a policy (e.g., implemented by an autowrap policy obligation). In an example, a user of Company A logs on to a computer with policy enforcer and encryption service module installed. The user attaches a production schedule spreadsheet which is encrypted with a local key to an email message and sends the email message to Customer B. A policy enforced by the policy enforcer specifies that all production documents send to a customer will be encrypted automatically. The policy is: FOR email.attach.class=production ON SEND TO *@CustomerB.com BY user=* DO ALLOW ON ALLOW INVOKE Auto-Encrypt(ShareKey=SK_CustomerB) FIG. 10 shows a flow 1001 for switching encryption keys on an email attachment to a shared key using policy obligation. In step 1002 , a user sends an email message with a production schedule spreadsheet product_schedule.xlsx.nxl attached. product_schedule.xlsx.nxl is encrypted with a local key. In step 1003 , a policy enforcer intercepts the send operation. In step 1004 , the policy enforcer sends information regarding the send operation including information on email attachment product_schedule.xlsx.nxl to a policy engine for evaluation. In step 1005 , the policy engine selects a subset of policies relevant to the send operation and email attachment which includes the above policy. The policy engine evaluates the select subset of policies. In step 1006 , the policy engine determines if the send operation should be allowed. In step 1007 , the send operation is allowed and policy obligation is auto-encrypt. The policy enforcer extracts an email attachment product_schedule.xlsx.nxl into a temporary file. In step 1008 , the policy enforcer invokes an auto-encrypt policy obligation on temporary file with shared key ring identifier SK_CustomerB. In step 1009 , the auto-encrypt policy obligation calls encryption service module with the temporary file and a shared key ring identifier SK_CustomerB to perform key switching on temporary file. In step 1010 , the policy enforcer reattaches the temporary file to the email message. In step 1011 , the send operation completes successfully and the email message is sent. In step 1012 , the send operation is denied. The policy enforcer blocks the send operation. In step 1013 , the send operation ends. Alternatively, step 1008 may check if the temporary file is encrypted and if the temporary file is encrypted with the correct shared key. If the temporary file is already encrypted with the correct shared key, the policy enforcer does not need to call auto-encrypt policy obligation. In an example, a user of Company A logs on to a computer with policy enforcer and encryption service module installed. The user uploads a report encrypted with a product group shared key to a customer support Web site for Customer B. A policy enforced by the policy enforcer specifies that all reports uploaded to a customer support site will be encrypted automatically. The policy is: FOR document.class=report ON UPLOAD TO *@CustomerB.com BY user=* DO ALLOW ON ALLOW INVOKE Auto-Encrypt(ShareKey=SK_CustomerB) FIG. 11 shows a flow 1101 for switching encryption keys to a shared key on file upload using policy obligation. In step 1102 , a user uploads a report DefectAnalysis.ppt.nxl to a customer support Web site accessible by Customer B. The report is encrypted with a product group shared key. In step 1103 , a policy enforcer intercepts the upload operation. In step 1104 , the policy enforcer sends information regarding the upload operation to a policy engine for evaluation. In step 1105 , the policy engine selects a subset of policies relevant to the upload operation which includes the above policy. The policy engine evaluates the select subset of policies. In step 1106 , the policy engine determines if the upload operation should be allowed. In step 1107 , the upload operation is allowed and policy obligation is auto-encrypt. The policy enforcer invokes an auto-encrypt policy obligation on the report DefectAnalysis.ppt.nxl with shared key ring identifier SK_CustomerB. In step 1108 , the auto-encrypt policy obligation calls encryption service module with the report DefectAnalysis.ppt.nxl and a shared key ring identifier SK_CustomerB to perform key switching. In step 1109 , the policy enforcer uploads the encrypted file DefectAnalysis.ppt.nxl to the support Web site. In step 1110 , the upload operation completes successfully. In step 1111 , the upload operation is denied. The policy enforcer blocks the upload operation. In step 1112 , the upload operation ends. Alternatively, step 1107 may check if the report is encrypted and if the report is encrypted with the correct shared key. If the report has the correct shared key, the policy enforcer does not need to call auto-encrypt policy obligation. In an example, a policy directs a data protection client and an encryption service module to switch the encryption key of a PED file to a shared key that allows the file to be decrypted on a home computer if a PED file is copied to a removable device. The policy is: FOR document.NXL_Encrypted=TRUE ON COPY TO [RemovableMedia]\** DO ALLOW ON ALLOW INVOKE Auto-Encrypt(SK_Homework) In an embodiment, a data protection client automatically converts a PED file with explicit file association to a PED file with implicit file association. By making file association of a PED file implicit, a user may open a PED file the same way as the user do on an unencrypted file. In an example, a user logs on to a computer with policy enforcer and encryption service module installed. The user opens an email message that has a PED file attachment with explicit file association (i.e., .nxl file extension). The user saves the PED file attachment to local disk and the PED file association automatically changed to implicit. A policy specifies that when a PED file with explicit file association is saved to local disk, convert file association of the PED file to implicit. The policy is: FOR document=*.nxl ON COPY TO C:\** BY user=* DO ALLOW ON ALLOW INVOKE StripFileExtension(“.nxl”) FIG. 12 shows a flow 1201 for converting file association of a PED file on copy action using policy obligation. In step 1202 , a user saves a PED file attachment important.doc.nxl to a local disk C:\mydocs. In step 1203 , a policy enforcer intercepts the save operation (which is a copy action in policy). In step 1204 , the policy enforcer sends information regarding the save operation to a policy engine for evaluation. In step 1205 , the policy engine selects a subset of policies relevant to the save operation which includes the above policy. The policy engine evaluates the select subset of policies. In step 1206 , the policy engine determines if the save operation should be allowed. In step 1207 , the save operation is allowed and policy obligation is StripFileExtension. The policy enforcer invokes a StripFileExtension policy obligation on the PED file important.doc.nxl to remove the .nxl file extension. In step 1208 , the save operation completes successfully and the user can open important.doc without awaring it is encrypted. In step 1209 , the save operation is denied. The policy enforcer blocks the save operation. In step 1210 , the save operation ends. In an embodiment, a data protection client and an encryption service module corporate to decrypt a PED file according to a policy. In an example, a user logs on to a computer with policy enforcer and encryption service module installed. The user downloads a manufacturing schedule spreadsheet encrypted with a product group shared key on an inter-department Web site to a local disk. A policy specifies that all reports downloaded to a customer support site will be encrypted automatically. The policy is: FOR document=http://inter-dept/manufacturing/schedule/**/*.nxl ON DOWNLOAD TO C:\** BY user=product-group DO ALLOW ON ALLOW INVOKE Decrypt FIG. 13 shows a flow 1301 for automatically decrypting a file using policy obligation. In step 1302 , a user downloads a spreadsheet schedule-2010.xlsx.nxl to a local directory c:\schedule. The spreadsheet is encrypted with a product group shared key. In step 1303 , a policy enforcer intercepts the download operation. In step 1304 , the policy enforcer sends information regarding the download operation to a policy engine for evaluation. In step 1305 , the policy engine selects a subset of policies relevant to the download operation which includes the above policy. The policy engine evaluates the select subset of policies. In step 1306 , the policy engine determines if the download operation should be allowed. In step 1307 , the download operation is allowed and policy obligation is decrypt. The policy enforcer downloads the encrypted file schedule-2010.xlsx.nxl to c:\schedule. In step 1308 , the policy enforcer invokes a decrypt policy obligation on the spreadsheet c:\schedule\schedule-2010.xlsx.nxl. In step 1309 , the decrypt policy obligation calls encryption service module with the spreadsheet c:\schedule\schedule-2010.xlsx.nxl and destination path c:\schedule to decrypt the document. In step 1310 , the download operation completes successfully with a decrypted spreadsheet c:\shcedule\schedule-2010.xlsx. In step 1311 , the download operation is denied. The policy enforcer blocks the download operation. In step 1312 , the download operation ends. Alternatively, step 1307 may check if the report is encrypted and if the report is encrypted with the correct shared key. If the report has the correct shared key, the policy enforcer does not need to call auto-encrypt policy obligation. In an embodiment, a data protection client automatically converts a PED file with explicit file association to a PED file with implicit file association. By making file association of a PED file implicit, a user may open a PED file the same way as the user do on an unencrypted file. In an embodiment, a PED file provides a unified means to collect information or document attributes (or “metadata”) from differ sources to enable consistent policy enforcement on information or a document across different operating systems, file systems, document repository or document archive, and whether information or a document is at rest, in motion or in distribution. A PED file contains a metadata section to store attributes associated with particular information or document. When a file is encrypted, the metadata section of a PED file may hold file system attributes, file system extended attributes, document properties, or document repository attributes. In an implementation, while the actual contents in a document file is prevented from being viewed (e.g., what is actually written in the document) because it is encrypted, metadata associated with the document file is accessible (e.g., the title of the document, when the document was last edited). For an unencrypted document, attributes may be stored in different locations. Some attributes are stored within a document. Some attributes are stored with the document on a file system. And some attributes are stored in a document repository with a document. Examples of attributes stored within a document include: 1) document properties of a Microsoft Word® document, Microsoft Excel® document, or Microsoft PowerPoint® document; 2) file properties of an Adobe PDF® file; 3) MIME header of an email message; 4) HyperText Transfer Protocol (or “HTTP”) header of a Simple Object Access Protocol (or “SOAP”) message; 5) HyperText Markup Language (or “HTML”) header; or more. Examples of attributes associated with a document on a file system include: 1) standard file attributes (e.g., file name, last modified time or owner); 2) extended file system attributes on UNIX® and LINUX® file systems; 3) data in alternative file stream on Microsoft NTFS® file system; 4) data in resource fork on Apple OS/X®; and more. Examples of attributes stored with a document in a document repository include: 1) document attributes stored with a document on a document management server (e.g., Microsoft SharePoint® or Documentum®); 2) document attributes stored with a document on an Enterprise Resource Planning (or “ERP”) system (e.g., SAP); 3) file attributes associated with a file on a source code control system (e.g., Subversion or Perforce); and more. When a PED file is decrypted, the information or document attributes in the metadata section may be stored as document properties in a document, or extended file system attributes on a file system. By having information or document attributes stored in a PED file, data protection clients may enforce polices consistently across different operating systems. An advantage of a PED file is it provides a portable means to transport information or a document of different types. A PED file is operating system, file system and file type agnostic. A PED file may be encrypted or decrypted on any operating system, stored on any file system, and encapsulate information or document of any format. In an example of the portable encryption, User B is an end user at Company X. User B is working on Company Y account and has access to proprietary customer information (i.e., information proprietary to Company Y). The following is an example flow of an implementation: (i) User B logs into her computer; (ii) User B brings up her email account and create a new email message addressed to her colleague at Company X, User C; (iii) User B attaches a file that is encrypted with a shared key and stored locally on her computer to the email message, and sends the email message with the encrypted file attached to User C; (iv) User C has a data protection client and an encryption service module installed on his system; (v) User C receives the email message and is able to read the encrypted file without taking any special action (i.e., the decryption process is invisible to him); (vi) After a few months and several new encryption keys have come and gone (new encryption keys are generated periodically to limit damage due to key lost), User C sends the encrypted file to User D of Company X; (vii) User D opens the encrypted file and is able to read it without delay or having to perform any special action; and (viii) end of example flow. To protected information or document in an organization, a policy author may develop policies that prevent a user from copying unencrypted information or documents to locations that may be accessed by a user who is not a member of the organization. In one example, a policy may be written based on resource attributes of information or document such that unencrypted information or document with an resource attribute indicating the information or document is confidential is not allowed to be copied to an external facing SharePoint site of a company. The policy is: FOR document.class=confidential AND document.NXL_Encrypted=FALSE ON COPY TO http://sharepoint.mycompany.com/site/external/** BY * DO DENY In another example, a policy may be written to apply encryption to unencrypted information or document via a policy obligation when the unencrypted information or document is about to be copied to a location that may not be protected by an information management system. In this case, a data protection client intercepts an operation that may cause unencrypted information or document to leave the protective realm of an information management system. To protect the unencrypted information or document, a policy applies an auto-encrypt policy obligation on the unencrypted information or document. On evaluating policies relevant to the intercepted operation, the policy engine determined an auto-encrypt policy obligation needs to be invoked. The data protection client invokes auto-encrypt policy obligation to encrypt the destination copy of the information or document. Some examples of operations that may allow unencrypted information or document to leave the protective realm of an information management system include: copying unencrypted information or document to a USB drive; attaching an unencrypted file to an email message addressed to a recipient outside an organization; uploading an unencrypted file to an online site outside an organization; and more. FOR document.NXL_Encrypted=FALSE ON COPY TO [RemovableMedia]\** OR http://sharepoint.mycompany.com/site/external/** BY * DO DENY In an embodiment, an encryption key access control is built on a trust system, wherein trust is established as a result access control decisions performed by a data protection client. Trust is established on the basis of: (a) a process of an application program instance (or application program process) making a request; (b) the encrypted information or document (or resource) being accessed; and (c) the user requesting access to the encrypted information or document. If access control decision has been made to allow access to the information or document by the application program process and by the user recently, trust has been established. If an encryption key request from an encryption service module satisfies the trust requirement, a data protection client provides the encryption key to the encryption service module. And the encryption service module will apply the encryption key only to requests from the application program process on the information or document. This encryption key access control mechanism is managed by a data protection client. Encryption key management on a computing device is thus part of a data protection client, integrated with access control and decoupled from encryption service module. Since encryption key access control is another form of access control, it integrates naturally with a data protection client. In an embodiment, combining a data protection client and an encryption service module provides application program independent access and use control on information or documents, encryption key management and persistent data protection on a computing device. While application program instrumentation provides data protection in a heterogeneous environment that consists of varying application programs, operating systems and computing devices. The information or documents being managed may be accessed from many different sources. For example, the type of computing devices that may be used to access information or documents in an organization includes: desktop computers, laptop computers, file servers, ERP systems, smart phones, tablet computers, and more. These devices may be running different operating systems including: Microsoft Windows®, Linux®, UNIX®, Apple OS/X®, Android®, and more. With a data protection client-based key management service, an encryption key can be securely managed by a data protection client on a computing device and made available to an encryption service on the computing device independent of the operating system running on the computing device. In another implementation, a method makes encrypted information or documents portable where encrypted information or documents may be accessed on different computing devices. The portable encryption technique described in this document provides a means to convert information or a document encrypted using a local key to a shared key so that the information or document may become accessible to other users. The transformation from local key to shared key may be carried out without user intervention. In another implementation, a method provides a transparent encryption means to allow automatic opening of a PED file with a default application program through Microsoft Windows® file association function. For example, the default application for a .docx file on Microsoft Windows® is typically Microsoft Word®. In another implementation, a method provides an attribute-based policy system where information or document access and use control may be enforced according to user attribute, document attribute, or a combination thereof. This description of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications. This description will enable others skilled in the art to best utilize and practice the invention in various embodiments and with various modifications as are suited to a particular use. The scope of the invention is defined by the following claims.
A technique and system protects documents at rest and in motion using declarative policies and encryption. Encryption in the system is provided transparently and can work in conjunction with policy enforcers installed at a system. A system can protect information or documents from: (i) insider theft; (ii) ensure confidentiality; and (iii) prevent data loss, while enabling collaboration both inside and outside of a company.
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FIELD [0001] The present invention relates to a method for preparing a coated current collector. DESCRIPTION OF THE RELATED ART [0002] In recent years one has become increasingly aware of the impact of human activities on the environment and the negative consequences this may have. Ways to reduce, reuse and recycle resources are becoming more important. In particular, clean water is becoming a scarce commodity. Therefore, various methods and devices for purifying water have been published. [0003] A method for water purification is by capacitive deionisation, using an apparatus provided with a flow through capacitor (FTC) for removal of ions in water. The FTC functions as an electrically regenerable cell for capacitive deionisation. By charging electrodes, ions are removed from an electrolyte and are held in an electric double layer at the electrodes. The electrodes can be (partially) electrically regenerated to desorb such previously removed ions without adding chemicals. [0004] The apparatus for removal of ions comprises one or more pairs of spaced apart electrodes (a cathode and an anode) and a spacer, separating the electrodes and allowing water to flow between the electrodes. The electrodes may be made by coating a current collector with a coating. The current collector is electrically conductive and transports charge in and out of the coating. [0005] The apparatus is provided with a housing comprising a water inlet to let water in the housing and a water outlet to let water out of the housing. In the housing of the apparatus for removal of ions, the layers of electrodes and spacers are stacked in a “sandwich” fashion by compressive force, normally by mechanical fastening. [0006] A charge barrier may be placed adjacent to an electrode of a flow-through capacitor. The term charge barrier refers to a layer of material which is permeable or semi-permeable and is capable of holding an electric charge. Ions are retained or trapped, on the side of the charge barrier towards which the like-charged ions migrate. A charge barrier may allow an increase in ion removal efficiency, which in turn allows energy efficient ion removal. [0007] Carbon based electrodes are a crucial component of FTC systems and their main function is to store ions during desalination. The capacity of the electrodes that are used in FTC stacks may demand improvements. At present the capacity of the commercially electrodes suitable for a FTC, such as the PACMM series electrodes by Material Methods (trademark), is in the order of 10-25 F/g. [0008] For reference, the electrodes of electrical double layer capacitors (also known as super capacitors) in general have a capacity of up to about 120 F/g, according to B. E. Conway, Electrochemical Super capacitors: Scientific Fundamentals and Technological Applications (Springer, 1999, ISBN: 0306457369). Commercially available electrodes consist of activated carbon particles which are fixed in a Teflon matrix. These commercial electrodes are used in fuel cells as well as in batteries, such as super capacitors. When such super capacitor electrodes are used in a FTC, the measured capacity according to the method in the examples below is in the order of up to 25 F/g and ion storage capacity is relatively low mainly because of poor wetting of the electrodes. [0009] In a FTC, salt is removed from water and therefore the carbon based electrodes should allow the penetration of water. However, the Teflon used in commercial electrodes expels water, which leads to suboptimal performance in a FTC. Carbon based electrodes, which do not use Teflon as a binder and are easily wettable by water are therefore being developed. In those electrodes the carbon particles are bonded together and onto the graphite current collector, for example by using a glue, for example a water based polyacrylate glue or epoxy resin. In order to increase the ion storage capacity of the electrodes, the carbon particles are blended with cationic or anionic polyelectrolytes or mixtures thereof. [0010] The carbon coating of the current collector may have a relatively low density of smaller than about 0.3 g/cm 3 of the dry weight. This may be caused by the carbon particles which may have a high degree of micro- and/or mesoporosity and in addition the carbon coatings may contain a high degree of void space. For example, less than half of the coating volume may contain carbon particles and the remaining space may be either filled with air or with water. In order to develop high density electrodes it is required that more of the empty space in the coating is filled with carbon particles, which in turn should also lead to an increase in ion storage capacity. [0011] Therefore, it is an object to provide improved coated current collectors, for use in an apparatus for deionization of water. SUMMARY [0012] Accordingly, an embodiment of the present invention provides a method for preparing a coated current collector, the method comprising: a preparing a coating paste comprising: i. dry coating materials comprising: 50-98.5 dry mass weight % of carbon having a specific surface area of at least 500 m 2 /g; 1-40 dry mass weight % of binder; 0.5-30 dry mass weight % of polyelectrolyte; and ii. 20-80% based on the total paste of solvent b applying the coating paste on one side of the current collector; c applying the coating paste on another side of the current collector; and, d drying the coating of the current collector at a temperature range from about 15° C. to about 120° C. [0022] The coating may be applied at both sides simultaneously. Drying the coated current collector may comprise drying at a temperature range from about 30° C. to 120° C. The temperature range may exclude a temperature of about 70° C. The solvent may be an aqueous solvent. The temperature range may comprise a temperature from about 15° C. to smaller than about 70° C. and from larger than 70° C. to smaller than 120° C. The temperature range may comprise a temperature from about 30° C. to about 69° C. and from larger than 71° C. to smaller than 120° C. [0023] An embodiment of the invention may further relate to a method for preparing a coated current collector, the method comprising: a preparing a coating paste comprising: i. dry coating materials comprising: 50-98.5 dry mass weight % of carbon having a specific surface area of at least 500 m 2 /g; 1-40 dry mass weight % of binder; 0.5-30 dry mass weight % of polyelectrolyte; and ii. 20-80% based on the total paste of solvent b applying the wet coating paste on one side of the current collector; c applying the wet coating paste on another side of the current collector; and, d drying the coated current collector so that the thickness of the wet coating paste layers shrinks more than 21%, more than 25%, more than 30% or more than 35%. [0033] The coating may be provided on both sides of the current collector simultaneously. Preparing the coating paste may comprise providing a dispersant other than the polyelectrolyte to the paste. [0034] An embodiment of the invention may relate to a double sided coated current collector, the coating comprising: a 50-98.5 dry mass weight % of carbon having a specific surface area of at least 500 m 2 /g; b 1-40 dry mass weight % of binder; and, c 0.5-30 dry mass weight % of polyelectrolyte, wherein the abrasiveness of the coating is such that less than 9.25 μm, less than 6 μm or less than 3.13 μm of the coating is removed per stroke in a linear scrubbing rig with a weight of 308 Kg/cm scrubbing over the coating. [0038] An embodiment of the invention may relate to a double sided coated current collector, the coating comprising: a 50-98.5 dry mass weight % of carbon having a specific surface area of at least 500 m 2 /g; b 1-40 dry mass weight % of binder; and, c 0.5-30 dry mass weight % of polyelectrolyte, wherein the dry mass density of the coating is larger than 0.3, larger than 0.35 or larger than 0.4 g/cm 3 . [0042] An embodiment of the invention may relate to a double sided coated current, wherein the coating comprises a dispersant other than the polyelectrolyte and a charge barrier is applied to the coating layer, the charge barrier comprising a membrane, selective for anions and/or cations, the charge barrier being applied to the coating layer as a further coating layer or as a laminate layer. [0043] An embodiment of the invention may relate to an apparatus for de-ionizing water comprising the coated current collector described herein. [0044] The coated current collector according to an embodiment of the invention has a higher carbon density, is stronger, and has improved ion storage capacity. In addition, the method should also allow large scale production at similar or lower cost compared to commercially available Teflon® based electrodes. [0045] The main reason for the higher carbon density may be the lower degree of void space in the coated current collector according to an embodiment of the invention. The carbon paste that is used for making the coated electrode has a high water content. The high water content is required, because at lower water levels the paste becomes too viscous, which makes it difficult, if not impossible, to spread onto the current collector. A rapid drying of the electrode at an elevated temperature, immediately after the coating has been applied, may lead to a collapse of the electrode layer, which in turn would give an increase in the density. [0046] The coated current collector of an embodiment of the present invention and the method to provide said coated current collector provides a higher ion storage capacity than the Teflon® based electrodes of the prior art. [0047] These and other aspects, features and advantages will become apparent to those of ordinary skill in the art from a reading of the following detailed description and the appended claims. For the avoidance of doubt, any feature of one aspect of the present invention may be utilised in any other aspect of the invention. It is noted that the examples given in the description below are intended to clarify the invention and are not intended to limit the invention to those examples per se. Similarly, all percentages are weight/weight percentages unless otherwise indicated. Numerical ranges expressed in the format “from x to y” are understood to include x and y. When for a specific feature multiple ranges are described in the format “from x to y”, it is understood that all ranges combining the different endpoints are also contemplated. BRIEF DESCRIPTION OF THE DRAWINGS [0048] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts and in which: [0049] FIG. 1 is a graph of the amount of NaCl removed by an apparatus for de-ionizing water using a current collector prepared with the method according to an embodiment of the invention; [0050] FIG. 2 is a graph of the conductivity of water coming from the apparatus for de-ionizing water using a current collector prepared with the method according to an embodiment of the invention; and, [0051] FIG. 3 is a graph of the total amount of NaCl removed per gram of activated carbon in the apparatus for de-ionizing water using a current collector prepared with the method according to an embodiment of the invention. DETAILED DESCRIPTION OF THE INVENTION [0052] Carbon electrodes, which are used in FTC cells, may be activated by bringing them in a concentrated salt solution. High neutral salt levels in the electrode promote the ion removal capacity as well as ion conductivity and hence speed of removal. However, during use of the FTC cells these ions can slowly leach out of the electrode material, which leads to a reduced electrode overall capacity to remove salt ions from a feed water solution as well as reduced kinetics of salt removal. In addition, high salt levels are required because of the presence of pore volume in the electrode matrix. [0053] Polyelectrolytes are being used to activate the carbon electrodes. One advantage of the polyelectrolyes is that they can adsorb onto the carbon particles, which prevent them from leaching out of the carbon electrode. Another advantage is that lower levels of polyelectrolytes are needed compared to when monovalent salt may be used, because no material is wasted to fill up pore volume. Polyelectrolyte [0054] The polyelectrolytes may be both anionic or cationic. The carbon electrodes containing the polyelectrolytes can be used in FTC cells that are built either with or without ion selective membranes. In principle either anionic or cationic polyelectrolytes can be used for both the anode and the cathode. Also mixtures of anionic and cationic polyelectrolytes can be used as well as zwitterionic polymers for both the anode and the cathode. Nevertheless, it is desired to use cationic polymers for the anode and anionic polymers for the cathode to obtain an increase in ion storage capacity. [0055] Suitable cationic polyelectrolytes in the context of an embodiment of the present invention are, for example, nitrogen based polyelectrolytes. Commercially available polyelectrolytes of this type are poly ethylene imines, such as Lupasol® (from BASF), polyquaterniums, such as the Merquat® polyquaterniums (from Nalco), poly amines, and poly vinyl pyridine and its derivatives, as well as cationic polyacrylamides, such as Accepta (from Accepta). [0056] Suitable anionic polyelectrolytes are sulphonated polymers and carboxylated polymers, and mixtures thereof. Commercially available anionic polyelectrolytes are polystyrene sulfonate, such as Flexan® (from National Starch) and polycarboxylates, such as the Sokolan™ series (from BASF) [0057] Both the cationic and anionic polyelectrolytes desirably have a molecular weight of at least 200 D, at least 500 D, or at least 1000 D. The molecular weight is desirably not more than 5,000,000 D, less than 100,000 D, or less than 10,000 D. The polyelectrolytes can be homodisperse or polydisperse covering a broad molecular weight range. [0058] The polyelectrolyte may be present in the coating in a concentration of at least 0.5%, at least 1%, at least 2% or at least 4% by weight of the dry coating. The polyelectrolyte is desirably present in a concentration of not more than 30%, not more than 20%, not more than 15%, or less than 10% by weight of the dry coating. The amount of carbon and polyelectrolyte may be adjusted so as to balance the capacitance of the anode and cathode electrodes. In practice this means that more polyelectrolyte and/or carbon may be used for the anode than for the cathode electrode. Binder [0059] The binder may be any conventional adhesive. The binder may be mixable with carbon material. In an embodiment, the binder is a water based adhesive. Binder systems may be selected for their ability to wet the carbon particle or current collector materials, or a surfactant or other agent may be added to the binder mixture to better wet the carbon particles or graphite foil. A dispersant or a dispersing agent is a surface active substance which may be added to the carbon coating paste to improve the dispersion of the carbon particles and by preventing them from settling and clumping throughout manufacture, storage, application and film formation. A dispersant may also be added to the carbon coating paste to stabilize the binder or improve the dispersion of the binder, especially for a binder that is a water based adhesive. [0060] A dispersant may be any type of surfactant or any type of emulsifier and may be selected on the basis of the hydrophilic-lipophilic balance number. The dispersant may be a synthetic detergent, soap, polymeric surfactant or any type of uncharged polymer, especially a water soluble polymer or any mixture thereof. A detergent surfactant can be anionic, cationic or nonionic or a mixture thereof. A surfactant may be sodium dodecyl sulphate, alkyl benzene sulphonate or alkyl ethoxylate and amine oxide surfactant. A dispersant that is used in the inkjet or paint and coating industry, such as Solsperse® and/or Disperbyk® and many others, may also be used. [0061] The dispersant may be similar as the polyelectrolyte. Advantageously, however the dispersant is different than the polyelectrolyte because that makes it possible to optimize both the electrolyte and the dispersant independent of each other. For example the optimal amount of polyelectrolyte may be different than the optimal amount of dispersant by optimizing them independently the dispersant and the polyelectrolyte may be present in the optimal amounts. [0062] Examples of uncharged polymer are polyethylene oxide, polyethylene glycol and polyvinyl pyrrolidone (PVP, e.g. the Luvitec® range or the PVP range from International Speciality Products (ISP)). [0063] A suitable commercial binder material may be a polyacrylic based binder such as the Fastbond™ range from 3M™. [0064] The binder may be present in the coating in a concentration of at least 1%, at least 2%, or at least 5% by weight of the dry coating. The binder is desirably present in the coating in a concentration of less than 50%, less than 40%, less than 30%, less than 20%, or less than 15% by weight of the dry coating. Carbon [0065] The carbon in the coating of an embodiment of the present invention comprises activated carbon, and optionally any other carbon material, such as carbon black. The activated carbon may be steam activated or chemically activated carbon, e.g., steam activated carbon, such as DLC A Supra Eur (from Norit). In an embodiment, the carbon has a specific surface area of at least 500 m 2 /g, at least 1000 m 2 /g, or at least 1500 m 2 /g. The anode and cathode may even be made out of different carbon materials. The higher the carbon surface area is, the higher is the ion storage capacity of the current collector. The specific surface area of carbon may for instance be measured by the B.E.T. method, as commonly used in the art. [0066] The carbon may be present in the coating in a concentration of at least 50%, at least 60%, at least 70%, or at least 75% by weight of the dry coating. The composition generally does not contain more than 98.5% by weight of the dry coating of carbon. Solvent [0067] The solvent, suitable for mixing the coating paste, may be any solvent suitable for dissolving the polyelectrolyte, such as an aqueous solvent or water. The solvent is generally evaporated from the paste to form a solid coating on the current collector. The evaporation may for instance be achieved by exposure to air (ambient or heated). The solvent may be present in an amount of 20-80% of the total paste, but is generally present in an amount of about 40-50% of the total paste, before drying. After drying, the coating desirably contains less than 25% solvent, less than 15% solvent, or less than 10% solvent. Method [0068] In an embodiment of the present invention, there is provided a method of preparing a coated current collector, the method comprising: [0069] preparing a coating paste comprising: carbon; binder; polyelectrolyte; and solvent [0074] applying the coating paste on a current collector; and [0075] drying the coated current collector. [0076] Drying the coated current collector may be done at a temperature range from 15° C. to 120° C., e.g., 30° C. to 120° C. The temperature range may exclude 70° C. The temperature range may be from 25° C. to smaller than about 70° C., e.g., 69° C. and from larger than 70° C., e.g., 71° C. to smaller than 120° C. [0077] For the manufacturing of the coated current collector, the carbon paste may be applied by paste-, blade-, dip-spray- or spin coating as single layers or multiple layers as well as by gravure roll coating, extrusion coating or by lamination or screen printing. For example, the screen printing process consists of forcing the carbon paste through a stencil covered substrate, e.g. grafoil® or through a wire mesh which has been mounted in a sturdy frame. In this case the carbon paste only goes through the open areas of the stencil and is deposited onto a printing substrate, e.g. grafoil®, positioned below the frame. Manual screen printing can be accomplished with only a few simple items: a sturdy frame, screen fabric, stencils, squeegees, and carbon paste. Automatic press equipment can be used which would greatly speed up the process. Dry Electrode [0078] The dry electrode made by the method of an embodiment of the invention, as coated onto the current collector, generally has a thickness of at least 50, at least about 100, or at least about 200 micrometers; and desirably less than 1000 or less than 500 micrometers. [0079] Commercially available electrodes, such as disclosed in U.S. patent application publication no. US2005/0042513, typically have a capacity of 10-25 F/g when applied to a FTC. The electrodes of an embodiment of the present invention generally have a capacity of more than 25 F/g, or at least 30 F/g. Current Collector [0080] The current collector may be any common type of current collector. The material of which the current collector is made, is a conducting material. Suitable materials are e.g. carbon, such as graphite, or a carbon mixture with a high graphite content, metal, such as copper, titanium, platinum, (stainless) steel, nickel and aluminium. The current collector is generally in the form of a sheet. Such sheet is herein defined to be suitable to transport at least 33 Amps/m 2 and up to 2000 Amps/m 2 . When a surface of graphite foil is used, such surface may be corona treated, plasma etched, chemically or mechanically abraded or oxidized to enhance binder adhesion. The thickness of a graphite current collector then typically becomes from 100 to 1000 micrometers, generally 200 to 500 micrometers. Charge Barrier Layer [0081] Charge barriers have been disclosed in U.S. Pat. No. 6,709,560 for use in a FTC. An embodiment of the present invention provides a coated current collector, as disclosed herein above, further comprising a charge barrier applied to the electrode coating layer, the charge barrier comprising a membrane, selective for anions or cations, the charge barrier being applied to the electrode coating layer as a further coating layer or as a laminate layer. [0082] In another embodiment, there is provided a system comprising the coated current collector as disclosed herein, comprising carbon, binder and polyelectrolyte, in combination with a separate conventional charge barrier as disclosed in U.S. Pat. No. 6,709,560. [0083] Suitable membrane materials may be homogeneous or heterogeneous. Suitable membrane materials comprise anion exchange and/or cation exchange membrane materials, desirably ion exchange materials comprising strongly dissociating anionic groups and/or strongly dissociating cationic groups. Examples of such membrane materials are Neosepta™ range materials (from Tokuyama), the range of PC-SA™ and PC-SK™ materials (from PCA GmbH), ion exchange membrane materials from Fumatec, ion exchange membrane materials such as the Ralex™ material (from Mega) or the Excellion™ range of heterogeneous membrane material (from Snowpure). Stack [0084] A FTC normally comprises at least one repeating unit of: an anionic current collector/electrode optionally an anion exchange membrane as charge barrier a conventional FTC spacer optionally a cation exchange membrane as charge barrier a cathode current collector/electrode. [0090] In practice the number of repeating units in a stack may be limited, for example, by the number of current collectors that can be practically bundled and connected to the connector or by the required stack compression force. In practice this means that a conventional FTC stack typically comprises 1 to 20 repeating units. The coated current collector may have a lower contact resistance between electrode and current collector, resulting in a lower required compression force per repeating unit. Therefore the required compression force for the same number of repeating units may be lower, or the number of repeating units in the FTC can be increased at constant compression force. It is desired that the number of repeating units in a FTC be at least 1, at least 5, at least 10, or at least 20. For practical reasons, the number of repeating units is generally not more than 200, not more than 150, not more than 100, or not more than 50. [0091] The stack may be compressed at a pressure of less than 3 bar, in an embodiment not more than 1 bar, not more than 0.3 bar, or less than 0.1 bar. [0092] The coated current collector of an embodiment of the present invention enables the configuration of a FTC stack in spirally wound form, amongst others, due to the lower electrical contact resistance of the carbon coated current collector. In such a spirally wound configuration, the FTC stack typically comprises at least 1 repeating unit. Typically the FTC stack in spirally wound form comprises less than 20 repeating units. Applications of the Coated Current Collector FTC [0093] The coated current collector is especially useful in a FTC device that requires low system cost, for example in a domestic appliance such as a coffee maker, espresso machine, washing machine, dish washer, refrigerator with ice or water dispenser, steam iron, etc, where the removal of hardness ions such as calcium and magnesium, as well as other ions is beneficial. The coated current collector can also be used for residential water treatment such as point of use devices as well as point of entry devices for whole households. The coated current collector can also be used for commercial and industrial applications, e.g. water treatment in agriculture (e.g. treatment of ground water and surface water), boiler water, cooling towers, process water, pulp and paper, laboratory water, waste water treatment, mining as well as for the production of ultra pure water. Finally the coated current collector may be used for the removal of problem ions such as nitrate in e.g. swimming pools and arsenic and/or fluoride in e.g. ground water. [0094] An embodiment of the invention will now be illustrated by means of the following non-limiting examples. EXAMPLE 1 [0095] Preparation of an anode coated current collector (total dry weight: 4 g). Dilute polyethyleneimine (Lupasol® from BASF) into water in order to obtain a 20% weight solution. Introduce 2.8 g of the 20% weight polyelectrolyte solution in a beaker. Add 4 g of water and mix to get a homogeneous solution. Add approximately 1.6 g of carbon particles (A Supra Eur from Norit) and mix until the particles are fully dispersed. Add the rest of the carbon particles (the total amount of carbon has to be 3.20 g) and mix until the particles are fully dispersed. Introduce 0.46 g of the binder and mix to get a homogeneous mixture. Check the viscosity of the mixture: if it is too viscous, add some water or if it is too liquid, wait a few minutes, some water will evaporate. Spread the paste on the graphite foil (speed: 5 mm/s). [0104] Anode Coating Composition Polyelectrolyte: polyethylenimine PEI from BASF (Lupasol®)→14% Activated carbon: A Supra Eur from Norit→80% Binder: Scotch-Weld/Pressure Sensitive Adhesive from 3M™→6% [0108] Preparation of a cathode coated current collector is done in a similar way except that the polyelectrolyte is replaced by an electrolyte specifically suited for a cathode, e.g. Flexan II, poly(4-styrenesulfonate) Mw: 130000 (from National Starch) [0109] The desalination results have been tested in a small FTC cell (Mini Cell), containing a single unit cell (total electrode area: 36 cm 2 ) as well as in a small FTC stack which can contain up to 13 repeating unit layers (total electrode area ca 1000 cm 2 ). [0000] TABLE 1 Measured thicknesses of dried electrodes for different applied coatings thickness, showing the effect of drying temperature. Thickness coating Thickness coating dried at room dried at 75° C. temperature (ca 24° C.) temperature % Meas- % Applied Measured (measured/ % ured (measured/ % (μm) (μm) applied) loss (μm) applied) loss 100 97.5 97.5 2.5 70.0 70.0 30.0 250 205 82.0 18.0 157.5 63.0 37.0 350 277.5 79.3 20.7 242.5 69.3 30.7 450 362.5 80.6 19.4 350.0 77.8 22.2 [0110] Table 1 shows that when the electrodes are dried in an oven at 75° C., then a significant reduction in electrode thickness is observed. For example, for a coating at an applied thickness of 250 μm (a characteristic thickness for carbon electrodes in FTC), a shrinkage of 37% is observed when the electrodes are dried at 75° C. compared to only 18% when dried at room temperature. This means that significantly denser electrodes can be obtained when the carbon coatings are dried at elevated temperatures. [0111] FIG. 1 is a graph of the amount of NaCl removed by an FTC apparatus for de-ionizing water using a current collector prepared with the method according to an embodiment of the invention. FIG. 1 shows the speed of ion adsorption as well as the maximum ion adsorption capacity for the carbon coated electrodes, which are dried at room temperature 3 as well as at 75° C. 1. The amount of NaCl removed is measured in mg NaCl per gram carbon and the amount is measured over a time period from 0 to 20:10 minutes. For comparison is included the results for a good quality commercial electrode 5 . Nevertheless, FIG. 1 shows that both coated electrodes outperform the commercial electrodes and also that the coatings that were dried at the higher temperature have about 20% higher ion storage capacity on a weight by weight basis. The ion adsorption onto different carbon electrodes was measured in a Mini Cell. [0112] In order to further test the coated electrodes in a FTC system, a small FTC stack, which contained 26 layers of carbon at a total weight of 9.724 g, was used. At a same weight basis, 18 layers of commercial Teflon based electrodes were used. [0113] FIG. 2 is a graph of the conductivity of water coming from an apparatus for de-ionizing water using a current collector prepared with the method according to an embodiment of the invention. FIG. 2 shows salt removal in a small FTC stack during 150 sec of desalination for current collectors coated at 75° C. 1, at room temperature 3 as well as for commercial electrodes 5 . The feed water contained 500 ppm NaCl and the flow rate was 100 ml/min. FIG. 2 shows that the desalination efficiency is higher for the coated electrodes compared to the commercial electrodes. The desalination continues longer for the electrode 1 comprising a coated current collector according to an embodiment of the invention and also the total amount of removed salt is higher for this coated current collector. Again the coatings that have been dried at 75° C. 1 outperform those that have been dried at room temperature 2 . More specifically, the electrodes that have been dried at 75° C. remove about 47% more salt than the commercial electrodes in a typical FTC experiment. [0114] FIG. 3 is a graph of the total amount of NaCl removed per gram of activated carbon in an apparatus for de-ionizing water using a current collector prepared with the method according to an embodiment of the invention 1 , a current collector dried at room temperature 24° C. 3 and commercial electrodes 5 . Again, the coatings that have been dried at 75° C. 1 outperform those that have been dried at room temperature 3 and the commercial electrodes 5 . Example 2 [0115] An abrasion test has been done with a linear scrubbing rig, which comprises a plateau onto which the coated electrode with an applied coating thickness layer of 250 μm is fixed and a moving arm having at the end a half cylindrical surface placed perpendicular onto the arm, where the cylindrical surface is made from PVC with a curvature of 1.5 cm and a width of 6 cm. Different weights can be placed on top of the cylinder and for an experiment a weight of 1850 kg was used such that there was (1850/6) 308 Kg/cm. The arm moves with a speed of 30 strokes/min. The total area that is used for the abrasion test is 120 cm 2 of coated electrodes and the assessment was made on 36 cm 2 electrode area. As a measure of abrasion resistance the number of strokes that are needed before the grafoil® current collector becomes visible to the eye was measured, after which the experiment was stopped. The more strokes that are needed the more abrasion resistant the electrodes are. Alternatively an ASTM D4060 Taber abrasion tester may be used. [0116] Table 2 shows the number of strokes that are needed before grafoil becomes visible to the bare eye for electrodes that have been dried for 2 hours at room temperature and for electrodes that have been dried for 2 hours at 80° C. [0000] Temperature Number Strokes 24° C. 27 80° C. 80 [0117] The coated current collectors with the higher abrasion resistivity also have an improved salt removal capacity over the coated current collectors with a lower abrasion resistivity. The abrasion resistivity is such that less than 9.25 μm (250 μm/27 strokes) per stroke is removed from the coating layer if the electrodes have been dried at more than 24° C. In an embodiment, the abrasion resistivity is such that 3.13 μm (250 μm/80 strokes) is removed from the coating layer if the electrode has been dried at 80° C. [0118] Carbon coated electrodes have excellent salt removal capacity compared with good quality commercial electrodes. The differences are becoming larger when the wet coatings are dried at increased temperatures. This also has advantages for the manufacturing of the coated electrodes because of reduced drying times and shorter production lines. In addition, the heat treated electrodes are more compact and more resistant to abrasion, which is another key advantage in the manufacture and handling of the electrodes. [0119] While specific embodiments of the invention have been described above, it will be appreciated that the invention may be practised otherwise than as described. The description is intended to be illustrative, not limiting. Thus, it will be apparent to one skilled in the art that modifications may be made to the invention as described without departing from the scope of the claims set out below.
Improved flow through capacitors and methods for purifying aqueous solutions. Despite recent developments, the capacity of the electrodes that are used in flow-through capacitor (FTC) stacks still demands improvement. It has been surprisingly found that at least one of these objects is met by FTC electrodes that are made with current collectors coated on both sides which are dried at a temperature range from 15° C. to 120° C.
2
This invention was made with government support under Public Health Service grants CA40272, P30 CA15704, and RR00166. The government has certain rights in this invention. This is a Divisonal of U.S. application Ser. No. 08/448,649, filed May 24, 1995, which is a Continuation of U.S. application Ser. No. 08/051,455, filed Apr. 21, 1993, now abandoned, which is a Divisional of U.S. application Ser. No. 07/562,008 filed Aug. 2, 1990, now U.S. Pat. No. 5,206,345. TECHNICAL FIELD This invention relates to genetic engineering involving recombinant DNA technology, and particularly to therapeutic methods and reagents for modulating the immune response including treating inflammation in a patient. BACKGROUND OF THE INVENTION The following abbreviations are used in this disclosure: CAM, cell adhesion molecules; EBM, endothelial basal medium; EC, endothelial cells; EDTA, ethylenediaminetetraacetic acid; EGF, epidermal growth factor; ELAM-1, endothelial leukocyte adhesion molecule-1; FBS, fetal bovine serum; HEV, high endothelial venules; HUVEC, human umbilical vein endothelial cells; ICAM-1, intracellular adhesion molecule-1; IL-1, interleukin-1; IL-1β, interleukin-1-beta; IL-4, interleukin-4; INF-γ, interferon-gamma; LDL, low density lipoprotein; LFA-1, lymphocyte function-associated antigen-1; LTBMC, long-term bone marrow culture system; mAb, monoclonal antibody; MLN, mesenteric lymph node; PBL, peripheral blood lymphocytes; PBS, phosphate-buffered saline; PMN, polymorphonuclear leukocyte; SEM, standard deviation; TNF-α, tumor necrosis factor-alpha; VCAM-1, vascular cell adhesion molecule-1; VLA-4, leukocyte integrin VLA-4; WM, Waymouth medium. Throughout the specification, the notation "(#)" is used to refer to the documents listed in the appended Citations section. Migration of lymphocytes from the bloodstream into surrounding tissues is a dynamic, multistep process initiated by attachment to the luminal surface of endothelial cells (EC) lining the postcapillary venules. Certain components of the microvasculature, notably the morphologically distinct high endothelial venules (HEV) found in lymphoid organs such as lymph nodes, Peyer's patches, and tonsils, continuously support lymphocyte binding and transmigration. Some adhesive interactions attendant with movement into these sites are, at least operationally, organ-specific (1-6). Others are mediated by cell adhesion molecules (CAM) that have more general tissue distributions, for example, ICAM-1/LFA-1 interactions (7-9). During both acute and chronic inflammation, microvascular endothelial cells at other sites can be induced to support traffic of various leukocyte subtypes (5, 10). Accumulation of lymphocytes in chronic inflammations, e.g., arthritic synovia, is usually accompanied by conversion of the local postcapillary venules to a cuboidal morphology and expression of new adhesive structures (3, 5). It has been suggested that lymphocyte adhesion to endothelial cells in chronic inflammatory lesions also incorporates an element of organ- or site-specificity (11). The complete identity and balance of inductive factors in the local microenvironment that contribute to the endothelial-cell "traffic" phenotype, and particularly its organ-specific character at some sites, have yet to be defined in molecular terms. Other factors are likely to be important, e.g., endothelial cell contact with the underlying extracellular matrix (12); but, clearly, release of proinflammatory cytokines in the local milieu contributes markedly to the upregulation of cell adhesion molecules on endothelial cells (13, 14). For example, interleukin-1 (IL-1), TNF-α, and IFN-γ have all been shown to increase adhesiveness of cultured endothelial cells for granulocytes and lymphocytes (15-23). In some cases these effects are paralleled by enhanced leukocyte migration to sites of cytokine injection in vivo (24, 25). Recently, much progress has been made in identification of specific cell adhesion molecules induced on endothelial cells by proinflammatory cytokines. IL-1, for example, induces endothelial leukocyte adhesion molecule-1 (ELAM-1), a member of the LEC-CAM (Lectin, EGF, Complement-Cellular Adhesive Molecule) family (19, 26), which is selectively adhesive for polymorphonuclear leukocytes and weakly adhesive for monocytes. Similarly, cytokine induction of intercellular adhesion molecule-1 (ICAM-1), a ligand for the leukointegrin LFA-1 (lymphocyte function-associated antigen-1), has been reported on endothelial cells (27). Recently, vascular cell adhesion molecule-1 (VCAM-1) was identified as a TNF- and IL1-inducible ligand for VLA4-mediated attachment of lymphocyte adhesion to human umbilical vein endothelial cells (HUVEC) (28-30). Although not directly linked functionally to lymphocyte transmigration, other cell surface markers associated with traffic endothelium in vivo have been shown to be induced by IFN-γ (15). Additional adhesive ligands of more limited tissue distribution, termed vascular addressing, MECA-79 and MECA-367, have been identified in lymph nodes and mucosal lymphoid tissues, respectively (31, 32). Whether these ligands can be induced in vitro by specific cytokines is not known at this point, but studies of transgenic mice suggest that IFN-γ may contribute to their expression in vivo (33). The capacity of cytokines to enhance lymphocyte adhesion to microvascular-derived endothelial cells has been analyzed in rodents and sheep (15, 24, 25). In humans, wherein most of the molecular definition of EC-CAM exists, cytokine induction has been studied almost exclusively using umbilical vein as the endothelial cell source (16-19). As pointed out recently by Issekutz (24), certain disparities exist between results obtained in these systems. Because of this and since our preliminary results indicated that large-vessel-and microvascular-derived endothelial cells might differ in cytokine responses vis-a-vis adhesive events, we endeavored to test how immunologically active cytokines affected lymphocyte adhesion to primate (macaque) microvascular endothelial cells. Further, since there have been suggestions of cytokine dependence for the traffic endothelial cell phenotype not only at sites of inflammation, but also for high endothelium in lymph nodes (34), mesenteric lymph nodes were used as one source of microvascular endothelial cells. SUMMARY OF THE INVENTION Our results indicate that IL1β- and IFNγ-induced microvascular endothelial cells behave similarly to HUVEC. In contrast, IL-4 on its own, and in combination with IL-1β, was a potent effector of lymphocyte adhesion to microvascular endothelial cells, but had only minimal effects on umbilical-vein-derived endothelial cells. A significant portion of the increased adhesion was due to upregulated expression of VCAM-1 or a serologically related molecule. The invention accordingly provides, in one aspect, a therapeutic method of modulating the immune response in a patient, by administering to the patient an amount of IL-4 effective to promote peripheral blood lymphocyte adhesion to microvascular endothelial cells in lymphoid organs and thereby modulate the patient's immune response. The IL-4 is preferably coadministered with IL-1β to the patient. In a representative embodiment, IL-4 is administered to a patient needing treatment for inflammation, to promote transmigration of lymphocytes from blood across postcapillary venules at sites of inflammation in the patient. Another aspect of the invention is the provision of an improved method of screening a cell line for the production of a binding partner that binds with a cell adhesion molecule. The method includes the steps of contacting the binding partner with cells bearing the cell adhesion molecule and detecting any binding reaction between the binding partner and the cells. The improvement involves contacting the binding partner with IL4-activated and nonactivated microvascular endothelial cells, and selecting cell lines that produce binding partners that bind to the IL4-activated microvascular endothelial cells but not to the nonactivated microvascular endothelial cells. As an additional screening step, the binding partners of the selected cell lines may thereafter be tested for the ability to block lymphocyte binding to cytokine-activated endothelial cells. In this manner, the invention provides immunological and peptide binding partners that specifically bind to IL4-activated but not nonactivated microvascular endothelial cells. The binding partners are preferably also characterized by the ability to block lymphocyte binding to cytokine-activated endothelial cells, and most preferably by binding to human VCAM-1 and to IL4- or TNFα-activated bone marrow stromal cells. A representative embodiment of this most preferred binding partner is mAb 6G10 produced by hybridoma ATCC No. HB 10519. In a related aspect, the invention provides a therapeutic method of modulating the immune response in a patient, by administering to the patient an agent that specifically binds to IL4-activated microvascular endothelial cells, in an amount effective to impede transmigration of cells, such as lymphocytes or tumor cells, that specifically bind to VCAM-1 from blood across postcapillary venules into extracellular fluid in the patient. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows photomicrographs of representative microvascular endothelial cells cultured in serum-containing (panel A) and serum-free media (panel B), as described in Example 1; FIG. 2 shows uptake of a representative endothelial-cell marker by cultured microvascular and other endothelial cells, as described in Example 1; FIG. 3 shows photomicrographs of lymphocyte adhesion to cultured microvascular endothelial cells following cytokine activation, as described in Example 2; FIG. 4 shows representative time courses of cytokine-induced lymphocyte adhesion to cultured microvascular endothelial cells, as described in Example 2; FIG. 5 shows stability of IL4/IL-induced lymphocyte adhesion to endothelial cells, as described in Example 3; FIG. 6 shows lymphocyte adhesion to IL4/IL1-activated endothelial cells is divalent cation dependent, as described in Example 4; FIG. 7 shows labeling of cultured microvascular endothelial cells with mAb 6G10, as described in Example 4; FIG. 8 shows monoclonal antibody 6G10 blocks the lymphocyte adhesion to IL4/IL1-induced macaque microvascular endothelium, as described in Example 4; FIG. 9 shows labeling of CHO transfected cells with mAb's 6G10 and 4B9, as described in Example 4; FIG. 10 shows that mAb 6G10 recognizes an approximately 110 kD molecule on cytokine-activated endothelial cells, as described in Example 4; FIG. 11 shows IL4/TNFα-enhancement of mAb 6G10-recognized antigen expression on bone marrow stromal cells, or described in Example 5; and, FIG. 12 shows that the VLA-4 receptor for VCAM-1 is expressed at high levels on bone marrow cells bearing the CD34 antigen, as described in Example 5. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Adhesion of lymphocytes to endothelial cells (EC) is the requisite first element in the multistep process of transmigration from blood across the postcapillary venules. Selective expression of cell adhesion molecules (CAM) by microvascular endothelial cells in lymphoid organs (e.g., lymph nodes) and during tissue inflammation modulates this traffic in a site-directed manner. CAM synthesis by endothelial cells is regulated in turn by cytokines released in the local microenvironment. Studies done largely with human umbilical vein endothelial cells (HUVEC) have implicated IL-1, IFN-γ, and TNF-α as cytokines that promote leukocyte adhesion to endothelial cells. In the work reported here, the responses of cultured microvascular endothelial cells derived from macaque lymph nodes to IL-1β, IL-2, and IL-4 were examined. Increases in lymphocyte adhesion following preculture of microvascular endothelial cells in IL-1β or IFN-γ were typically two-to fourfold above controls and comparable to those reported for HUVEC. IL-2 had no effect. The most striking finding followed stimulation with IL-4. While only marginal effects on large vessel cultured endothelial cells were seen, this cytokine markedly enhanced adhesion to microvascular endothelial cells. IL-4 induced adhesion was observed as early as 4 hours after induction, plateaued by 24 hours, was stable through 72 hours of culture, but decayed to basal levels within 72 hours after removal of IL-4 from the cultures. IL-1β, but not IL-2 or IFN-γ, synergistically enhanced the action of IL-4 on cultured microvascular endothelial cells to promote lymphocyte binding. Adhesion triggered in this manner required de novo protein synthesis. However, the avidity of IL4-activated microvascular endothelial cells for lymphocytes, and analyses of kinetics, cation and temperature dependence, and/or lack of blockade with mAb's to ELAM-1, ICAM-1, and MECA-79 indicated that these CAM were not central to the phenomenon. To aid identification of the relevant CAM, mAb's specific to IL4-induced microvascular endothelial cells were produced. One of these, 6G10, blocked up to 90% of lymphocyte adhesion to IL4-induced microvascular endothelial cells and reacted specifically with CHO cells transfected with human VCAM-1, an endothelial ligand of the β1 integrin, VLA-4. Our results indicate that IL-4 may have potent effects on lymphocyte recirculation in vivo and that endothelial cell subtypes may regulate VCAM-1 differentially in response to specific cytokines. Numerous studies suggest that recruitment of leukocytes to sites of both acute and chronic inflammation is triggered by increased expression and function of cell adhesion molecules (CAM) on endothelium as well as on blood leukocytes (3, 10, 14). That elevated CAM function is accomplished in part by release of proinflammatory cytokines such as IL-1, IFN-γ, and TNF-α is also well documented in the recent literature (11, 13, 23, 28). Other elements of the complex process of vessel transmigration, lateral movement on the endothelial surface, and diapedesis, for example, are undoubtedly facilitated or inhibited by other cytokines, e.g., IL-8 (51). Moreover, some endothelial CAM are more adhesive in vitro for certain leukocyte subpopulations than others (17, 19, 52). Also, kinetics of individual CAM expression may differ, and their induction by individual cytokines may be selective. Therefore, local secretion of these soluble molecules could provide a means whereby the influx of lymphoid; monocytic, and granulocytic cells could be regulated with a degree of independence. The studies reported here were undertaken because of dissimilarities between some of the in vitro data on leukocyte adhesion to cytokine-stimulated endothelium and in vivo findings on recruitment to sites of cytokine injection. For example, while IFN-γ markedly stimulates lymphocyte migration to skin after local injection (23, 53, 54), significant but less striking effects on lymphocyte adhesion to cultured human endothelium were reported (20, 27). Reciprocally, IL-1, which stimulates adhesion well in vitro, did not enhance recruitment to skin at injection sites in rats (23, 54). In principle, these disparate observations could be explained by species-specific differences since most in vitro studies have used human umbilical vein endothelial cells as the cellular substrate for adhesion, while in vivo experiments have typically utilized rodent or ovine models (24, 25). Alternatively, distinctions between microvascular and large vessel derived endothelial cells could be responsible. For example, Issekutz (24) and Hughes et al. (55) did find that IFN-γ treatment of rat microvascular endothelial cells significantly increased the binding of lymphocytes. An additional explanation for the disparity between in vivo and in vitro data suggested by the work of Oppenheimer-Marks and Ziff (56) is that IFN-γ promotes both adhesion and subsequent migration across endothelium, while IL-1 may only stimulate the initial lymphocyte binding. To help resolve some of these issues, we developed a system to examine adhesion of lymphocytes to cultured lymph node microvascular endothelium. Relatively pure cultures of endothelial cells were propagated from macaque lymph nodes as disclosed below. These cultured cells had the characteristic dome-shaped, cobblestone morphology of cultured endothelial cells and expressed markers characteristic of endothelium, such as uptake of acetylated-LDL. Our results are summarized in Table 1. TABLE 1______________________________________Effect of cytokines on cultured microvascular endothelium.Medium Cytokine(s) none IL-1β IL-2 IFN-γ______________________________________Complete EBM none 44.5 ± 188 ± 46.0 ± 65.5 ±(2% FBS) 12.0 21.9 6.9 14.8 IL-4 200 ± 615 ± 230 ± 251 ± 37.2 74.4 57.5 22.0Complete CS-1.55 none 250 ± 656 ± 291 ± 452 ±(serum-free) 53.7 67.7 57.8 36.9 IL-4 684 ± 1226 ± 633 ± 856 ± 48.4 99.3 88.2 107.2______________________________________ Endothelial cells were treated with IL1β (1 ng/ml), IL2 (100 u/ml), IL4 (10 ng/ml), IFNγ (100 u/ml), or their combination, or left unstimulated for 24 hr as indicated. After removal of cytokines, PBL were added to each well, the adhesion assay was performed (constant agitation for 30 min at +4° C.) and lymphocytes bound to endothelial cells were counted. Each value represents a mean number of adherent lymphocytes per mm.sup.2 ± SEM. In general, the results for IL-1β, IFN-γ, and IL-2 were similar to those reported previously for HUVEC. Both IL-1β and IFN-γ stimulated lymphocyte adhesion, albeit more strongly and consistently in the case of IL-1β, while IL-2 was without any noticeable effect. The most striking finding was that IL-4 treatment of endothelial cells markedly increased their adhesiveness for lymphocytes. This was apparent as early as 4 hours after treatment, reached a plateau by approximately 12-24 hours, and was maintained for at least 72 hours. The effect required de novo protein synthesis and continued presence of cytokines for maintenance. Interestingly, this robust effect of IL-4 was not observed on HUVEC, or on endothelial cells from macaque aorta; in these cases IL-4 had either no effect or only marginally enhanced lymphocyte adhesion (J. Harlan, J. Pober, personal communications; Masinovsky and Gallatin, unpublished data). Typically, the maximal increase over background in lymphocyte adhesion was in the same range (approximately twofold) as that reported recently for IL4-treated HUVEC by Thornhill et al. (52). The mechanisms underlying this differential response of the two endothelial cell types is not known. However, it is probably not explained by a relative absence of IL-4 receptors per se on HUVEC. In macaque, at least, IL-4 receptor expression on large vessel and microvascular endothelial cells is roughly equivalent (Masinovsky and Beckmann, unpublished data). The involvement of LFA-1/ICAM-1 mediated adhesion, at least as an obligatory part of this phenomenon, could be excluded because the IL4-induced binding was: a) not sensitive to cold temperature, b) primarily calcium dependent, and c) not blocked by addition of mAb to these CAM. Similar antibody inhibition tests excluded a necessary involvement of MECA-79, CD44, and class II MHC in the process. Although not directly excluded, the utilization of ELAM-1 as an adhesive component seems unlikely. Kinetics of its induction versus the adhesion observed here are different, and ELAM-1 is preferentially adhesive for neutrophils and monocytes rather than for lymphoid cells. The fact that one mAb, 6G10, specifically reactive with IL4-induced microvascular endothelial cells, blocked lymphocyte adhesion and reacted selectively with human VCAM-1 transfectants strongly suggests that VCAM-1 or a serologically closely related molecule (of 100-110 kD, see below) mediates lymphocyte binding in this system. It might not be the only relevant structure since other cell surface molecules were induced by IL-4 on microvascular endothelial cells (Masinovsky and Gallatin, unpublished data). However, the identification of these additional components, as cell-adhesion molecules, has not been established. VCAM-1, also known as INCAM-110, was recently identified on TNF-α- and IL1-induced HUVEC (28, 29). Molecular analyses reveal that it is a member of the immunoglobulin supergene family and has as one ligand the β1-integrin, VLA-4 (29, 30). Although its precise physiologic role during inflammation has yet to be defined, recruitment of lymphocytes to chronic inflammations such as arthritic synovia is one possibility. Involvement of VCAM-1, or a related molecule, in normal traffic through mucosal lymphoid tissue may also occur since the α-chain of VLA-4 has been implicated in lymphocyte binding to high endothelium in Peyer's patches (2). VCAM1-mediated adhesion may selectively recruit only certain lymphocyte subsets since VLA-4 expression is not uniform on all peripheral lymphocytes. In fact, direct evidence for lymphocyte subset biased adhesion to cytokine activated endothelium was provided recently by Damle and Doyle (57). The involvement of VLA-4/VCAM-1 mediated adhesion was not tested in their study, but this would be an intriguing possibility that could explain their data in part. In addition to its function in lymphoid traffic, VCAM-1 may also be an important factor in tumor metastasis (28). Unfortunately, other mAb's currently available to VCAM-1 react poorly with nonhuman primate endothelial cells (Masinovsky and Gallatin, unpublished data; M. Bevilacqua, J. Harlan, J. Pober, personal communication). Since mAb 6G10 reacted with both human and macaque endothelial cells it should provide a useful tool to address the issues of tissue distribution, in vivo function, and the role of IL-4 in VCAM-1 induction. For example, tests to determine if systemic administration of IL-4 results in VCAM-1 induction could provide insight into the mechanisms underlying vascular leakage and the lymphocytopenia observed during clinical therapy with this cytokine. That IL-4 may regulate lymphocyte traffic is perhaps not surprising in hindsight. Originally described as a B cell stimulant (58), IL-4 has receptors on a variety of cell types, including nonhemopoietic cells (41-44), and triggers many distinct responses. IL-4 promotes adhesion between B and T cells, in part by upregulation of class II MHC molecules (59). That IL-4 acted synergistically with IL-1β to activate microvascular endothelial cells is a novel finding but not without precedent. IL-4 acts together with IL-2 and IL-5 to regulate secretion of different immunoglobulin isotypes (60), with GCSF to promote granulopoeisis (46), and with IL-3 to regulate the differentiation of mast cells (61). Similarly, synergy between IL-1 and TNF has been reported in inducing migration of PMNs during inflammation (62). Although antagonism between IL-4 and IFN-γ has been reported during B cell activation (63, 64), we did not observe an effect of this type on cultured endothelial cells (Table 1). The mechanism underlying synergy between IL-1 and IL-4 in this system is at present unknown. While not formally excluded, it seems unlikely that either cytokine exerts its effect solely through induction of the other. When tested alone over a wide range of concentrations, neither cytokine induced as much adhesion as when the two were applied together. Nonetheless, it will be interesting to determine if either IL-4 or TNF-α, which are both good inducers of VCAM-1, act directly on endothelial cells or indirectly through induction of a second soluble mediator. EXAMPLE 1 Propagation of microvascular endothelial cells To initiate this work, a procedure for obtaining uniform cultures of endothelial cells from lymph nodes was derived. Small colonies with endothelial morphology in cultures prepared from macaque mesenteric lymph nodes, as outlined in the appended Materials and Methods section, were recognized 2-3 days after primary plating. Cells had a polygonal shape with few contacts between them. By the 5th to 7th day the cultures grew to confluency, most of the growth occurring at the periphery of the colony, at which point the first selective removal of fibroblasts and other nonendothelial cells was carried out by limited trypsinization. When combined with selective growth media, this procedure typically yielded cultures which were virtually free of contamination by cells having a fibroblastoid morphology or markers characteristic of dendritic or monocytic cells. Although endothelial cells were successfully grown in all three of the media preparations used, the media varied in their relative capacities to selectively propagate endothelial cells maintaining typical endothelial markers and cytokine responses (see below). For example, morphological differences were observed between microvascular endothelial cells grown in different media, with serum-containing media giving a higher frequency of cells having a cobblestone morphology characteristic of endothelial cells (FIG. 1, panel A). Reciprocally, the most rapid and selective growth of endothelial cells compared to nonendothelial cells was obtained with the serum-free CS-1.55 medium (panel B). Referring to FIG. 1 in more detail, the two photomicrographs, of live cultured microvascular endothelium of macaque mesenteric lymph nodes, show the dome-shaped appearance of cells grown to confluency in complete EBM containing 2% FBS (panel A), as compared to the more elongated cells in serum-free endothelial cell medium, complete CS-1.55 (panel B). Scale bars indicate 100 μm. Referring to FIG. 2, uptake of acetylated-LDL, a marker associated with endothelium, by endothelial cells grown in CS-1.55 was similar to that observed for endothelial cells from aorta. In particular, FIG. 2 is a flow cytometric analysis of acetylated-LDL uptake by cultured macaque endothelial cells grown in CS-1.55 from: aorta (heavy continuous line); microvascular endothelial cells of mesenteric lymph nodes (MLN) (dashed line); MLN microvascular endothelial cells activated with IL-4 (10 ng/ml) and IL-1β (1 ng/ml) for 24 hrs (dotted line); and negative-control cultured human foreskin fibroblasts (HFF) (thin continuous line). Cells were exposed to acetylated-LDL (10 μg/ml) for 6 hr, then dislodged with trypsin-EDTA, and analyzed on a Coulter EPICS 720-2 flow cytometer; see Materials and Methods. Endothelial cells grown in serum-free medium were passaged successfully more than six times without any apparent morphological changes. In contrast, usually after the third passage, microvascular endothelial cells grown in the presence of serum assumed a more flattened shape, frequently losing contacts with the substrate. Accordingly, for serum-containing cultures, only cells from the first two passages were used for adhesion assays. EXAMPLE 2 Lymphocyte adhesion to cultured cytokine-induced microvascular endothelial cells The capacities of IL-1β, IL-2, IL-4, and IFN-γ to induce endothelium to be more adhesive for lymphocytes was examined as follows. Briefly, cultures of microvascular endothelial cells from macaque mesenteric lymph nodes were cultured in the presence of these cytokines for varying lengths of time, washed, and assayed for lymphocyte adhesion as described below (see Materials and Methods). Monocytes were removed from the lymphocyte suspension prior to assay. The results are shown in Table 1 and FIGS. 3 and 4. FIG. 3 shows photomicrographs of PBL adhesion to cultured endothelial cells from mesenteric lymph nodes of Macaca nemestrina. Endothelial cells were grown to confluency and activated by cytokines for 24 hr. Following the adhesion assay, cells were fixed with 1% glutaraldehyde in PBS. The panels (a-d) indicate endothelial cell activation with: (a) IL-1β (1 ng/ml); (b) IL-4 (10 ng/ml); (c) IL-1β (1 ng/ml) and IL-4 (10 ng/ml); and (d) control, no interleukins added. Arrows indicate adherent lymphocytes; arrowheads, endothelial cells; scale bar, 100 μm. FIG. 4 plots adhesion of PBL to cytokine-activated cultured microvascular endothelial cells at different cytokine concentrations and incubation times. Before each adhesion assay, endothelial cells were treated with cytokines (solid circles, IL-4; open circles, IL-1β; triangles, IL-4in the presence of 1 ng/ml of IL-1β) for the time indicated, which incubation was followed by the adhesion assay. Lymphocyte binding to these endothelial cells was determined by visual count of attached lymphocytes. Each point represents the mean number of attached PBL±SEM. As anticipated from previous reports (16, 18, 20), after 24 hrs of induction, both IL-1β and IFN-γ treatments yielded similar increases in the number of adherent lymphocytes. Stimulation indices of 2 to 4 compared to controls were typical for cytokine concentrations in the range of 1 pg/ml to 10 ng/ml (FIG. 3 and Table 1). IL-2 had no effect on lymphocyte binding at any concentration tested (Table 1, and data not shown). In contrast to the rather minimal effects observed with the other cytokines, IL-4 treatment consistently yielded the most dramatic increase in lymphocyte adhesion (FIGS. 3 and 4, and Table 1). The level of PBL adhesion to IL4-induced endothelial cells exceeded that of the control (no cytokines) by up to 45-fold (FIG. 4, 24 hr). The optimum concentration of IL-4 that promoted abundant adhesion of lymphocytes to endothelial cells was in the range of 100 pg/ml to 10 ng/ml; this optimum was common for all time periods (4, 24, and 72 hrs) of endothelial cell exposure to this cytokine (FIGS. 3 and 4). At these concentrations, the absolute numbers of lymphocytes bound to IL4-exposed endothelial cells were consistently in the range of 200-1300 lymphocytes/mm 2 , while on the control endothelial cells only 5-40 lymphocytes/mm 2 were observed. The stimulation index (which ranged from 2 to 45) varied among different animals used as a source for microvascular endothelium, and was lower for endothelial cells propagated in serum-free medium, due essentially to the higher background adhesion on endothelial cells cultured in this manner (Table 1). IL-4 promoted adhesion by acting on microvascular endothelial cells rather than on lymphocytes, since addition of an anti-IL-4 antibody to the cultures during the assay, or addition of IL-4 to lymphocyte suspensions for 30 min prior to assay, did not affect the lymphocyte binding to cultured endothelial cells. IL4-induced adhesion was detected as early as 4 hr after cytokine treatment, plateaued by 12-2 hr, and remained in evidence through at least 72 hr in the continued presence of IL-4 (FIG. 4). The effect of IL-4 was relatively specific to cultured microvascular endothelial cells, since addition of this cytokine to other adherent cells, such as fibroblasts, which have functional receptors for IL-4 (41-44), did not result in increased lymphocyte adhesion in our system (data not shown). At the highest tested concentrations of IL-4 (50-100 ng/ml) and of IL-1β (5-10 ng/ml), cultured microvascular endothelial cells underwent morphological changes, converting from a cobblestone phenotype to a more flattened appearance with fewer cell-cell contacts and a detachment of cells from the plates. These changes were apparent after 24 hrs of cytokine exposure and resulted in decreased lymphocyte adhesion per unit area of the culture well. EXAMPLE 3 Synergism between IL-4 and IL-1 in promoting lymphocyte adhesion to cultured microvascular endothelial cells Because IFN-γ, IL-1β, and IL-4 all enhanced adhesion to microvascular endothelial cells, and since these cytokines had been reported to synergize with other interleukins in promoting various hemopoeitic activities (45, 46), we tested their effect on microvascular endothelial cells in combination. After 24 hours of costimulation the effects of IL-4 and IFN-γ were at best additive with no significant synergy in evidence (Table 1). Similarly, additive but not synergistic activity was observed when IL-1β and IFN-γ were applied in conjunction (data not shown). In contrast, the amount of lymphocyte adhesion observed when both IL-4 and IL-1β were added to the microvascular endothelial cell cultures was markedly increased over that expected from purely additive effects (FIGS. 3 and 4, Table 1). When the amount of IL-1β was held constant (0.1 or 1 ng/ml) and varying amounts of IL-4 were added, synergistic activation of cultured endothelial cells was observed over a wide range of cytokine concentrations (FIG. 4). In the presence of as little as 1 pg/ml of IL-4, addition of IL-1β increased lymphocyte adhesion 2.5 to 7 times compared to that detected with IL-4 alone (FIG. 4). For lower concentrations of IL-1β (0.1 ng/ml), synergistic lymphocyte adhesion was approximately half of that observed at 1 ng/ml. Addition of IL-1β did not significantly alter the kinetics of the response to IL-4, nor did it change the optimum concentrations of IL-4 that promoted adhesion (FIG. 4). The super-additive effect of IL-1β and IL-4 was manifest only under certain culture conditions. For endothelial cells grown in serum-free medium, CS-1.55, which typically had background adhesion 5-10 fold higher than that observed in other media, the effects of these two cytokines were only additive (Table 1). Referring to FIG. 5 in more detail, after 24 hr incubation with IL-4 (1 ng/ml) and IL-1β (1 ng/ml), the cytokines were removed. The adhesion assay was conducted after additional incubation without any Iymphokines. Each point (open circles) represents the mean adherence±SEM of eight readings. Control endothelial cells (solid circle) received no cytokine added. The combinatorial effect of IL-1β and IL-4 on lymphocyte binding to microvascular endothelial cells required de novo protein synthesis. If after 2 hr of cytokine activation with IL-1β (1 ng/ml) and IL-4 (10 ng/ml), the metabolic inhibitor, emetine, was added, adhesion observed 2 hr later was inhibited to 10% of that seen without addition of emetine. In similar experiments, if emetine was added after 70 hr of endothelial cell activation, adhesion measured at 72 hr was unaffected compared to controls. Once induced, the adhesive function of endothelial cells was relatively stable over time. Maintenance of the relevant cell adhesion molecules in a functional form did depend, however, on continued presence of the cytokines. When endothelial cells were incubated with IL-1β and IL-4 for 24 hr, and then the interleukins were removed, the capacity to support lymphocyte adhesion was almost unchanged during the first 8 hr, decayed by 50% at 24 hr, and returned to essentially background levels by 72 hr (FIG. 5). EXAMPLE 4 Identification of one CAM involved in IL-4 induced lymphocyte adhesion to microvascular endothelial cells A priori, IL-4's effects in this system could be manifest through induction of known adhesion molecules, or might involve expression of novel CAMs. To examine these possibilities, the following approaches were taken. First, the temperature dependence and cation requirements of lymphocyte binding were determined. Temperature dependence was minor, with robust adhesion observed at both 4° and 37° C. (FIGS. 3 and 4, Table 1, and data not shown). Also, lymphocyte binding was divalent cation dependent, with a primary requirement for calcium rather than magnesium ions (FIG. 6). Both of these facts tend to exclude LFA-1 (CD11/CD18)/ICAM-1 mediated interactions since these are sensitive to low temperature and utilize magnesium as the preferred cation (47). Referring to FIG. 6 in detail, endothelial cells were activated with IL-1β (1 ng/ml) and IL-4 (10 ng/ml) for 24 hr. Subsequently, endothelial cells were fixed in 1% paraformaldehyde in PBS, washed, and the adhesion assay was conducted in PBS-based medium containing 1% BSA and 1% glucose to which Ca ++ or Mg ++ were added as shown. Each bar represents the mean number of adherent lymphocytes±SEM of four readings. Closed bars: IL1/IL4-activated endothelial cells; open bars: control, no cytokine added. Secondly, the sensitivity of IL-4 induced adhesion to blockade by mAb known to interfere with cell-cell interactions mediated by the CAMs, CD44, MECA-79, and by interactions between LFA-1 and ICAM-1 was tested by pretreating the relevant cell (i.e., lymphocyte or endothelial cell) with each mAb prior to assay (see Materials and Methods). Although all these reagents reacted well with macaque endothelial cells and/or lymphocytes in culture or in tissue sections, none of them interfered significantly with lymphocyte binding under these conditions. Since upregulation of class II MHC molecules on endothelium had been reported after induction with IFN-γ and TNF-α (50-52), an anti-class II MHC mAb, Hb10a, was also tested and likewise did not effect lymphocyte attachment (data not shown). A similar assessment could not be made for ELAM-1 since the available antibodies against this molecule did not react well with macaque endothelial cells. Nonetheless, other differences between ELAM-1 mediated adhesion and that observed following IL-4 stimulation were inconsistent with involvement of this particular CAM in a primary role (see above). In parallel experiments conducted with two different antibodies (4B9 and E1/6) against human VCAM-1 (aka INCAM-110 (28-30)), only weak reactivity with cytokine-induced microvascular endothelial cells was detected by immunofluorescent confocal microscopy (data not shown). However, in one experiment out of four conducted, an inhibition (40%) of lymphocyte binding to IL4/IL1-induced microvascular endothelial cells was detected. Although inconclusive, this result suggested that VCAM-1 might contribute to the process of attachment, especially since mAb's 4B9 and E1/6 were relatively species specific. These mAb's reacted poorly in immunocytochemical tests of macaque tissues. To resolve the issue, mAb's specific to IL-4 induced macaque endothelial cells were prepared (see Materials and Methods). Briefly, hybridomas derived from fusions using spleen cells from mice immunized with cytokine-stimulated endothelial cells were first screened by ELISA for selective reactivity with IL4/IL1-activated endothelium. Positive clones were tested secondarily for their ability to block lymphocyte binding to endothelial cells under various conditions of cytokine treatment. One mAb elicited in this manner, 6G10, detected on cultured endothelial cells a cell-surface antigen whose expression paralleled the amount of lymphocyte adhesion induced by each cytokine (i.e., IL1β+IL-4>IL-4>IL-1β, FIG. 7). More importantly, 6G10 blocked up to 80% of lymphocyte adhesion occurring after endothelial cell treatment with IL-1β/IL-4 (FIG. 8). To clarify the identity of the structure recognized by mAb 6G10, this reagent was tested by indirect immunofluorescence for reactivity with CHO cells transfected with cDNAs encoding human ELAM-1, ICAM-1, VCAM-1, or CD4 as a control. We found that mAb 6G10, similar to mAb 4B9, bound specifically with transfectants expressing the product of the VCAM-1 gene (FIG. 9). No reactivity was observed on the other transfectants. By extension then, lymphocyte binding to IL-4 stimulated endothelial cells in this system most probably utilizes the macaque homologue of human VCAM-1 or a serologically related molecule as a major adhesive component. Referring to FIG. 7 in detail, endothelial cells were activated for 24 hr with: panel A, control, no cytokine added; panel B, IL-1β (1 ng/ml); panel C, IL-4 (10 ng/ml); and panel D, IL-4 (10 ng/ml) and IL-1β (1 ng/ml). After stimulation, unfixed cells were exposed to mAb 6G10 for 2 hr at room temperature, which was followed by exposure to biotinylated secondary antibody, avidin-FITC labeling, and analysis on Bio-Rad laser scanning confocal microscope. Note an increase of immunofluorescence with IL-4 and IL-1β+IL-4 activation of endothelial cells. Scale bar is 50 μm. Referring to FIG. 8, endothelial cells were activated with IL-4 (10 ng/ml) alone or in a combination with IL-1β (1 ng/ml) for 24 hr. After removal of cytokines, cells were exposed to either mAb 4B9 or 6G10 for 30 min, and the adhesion assay was conducted. Each bar represents mean number of adherent lymphocytes±SEM of four readings. FIG. 9 shows immunofluorescence of: panel A, human VCAM-1 transfectant labeled with 6G10; panel B, same as in (A) but labeled with 4B9; panel C, human ICAM-1 transfectant labeled with 6G10; and panel D, human ELAM-1 transfectant labeled with 6G10. Scale bar is 100 μm. FIG. 10 shows radioimmunoprecipitation of cell surface molecules of microvascular EC with mAb 6G10. EC were grown to confluency in complete EBM and were either activated with IL-4 (10 ng/ml), TNF-α (10 ng/ml), or IL-4 (10 ng/ml) and TNF-α (10 ng/ml), or served as a control receiving no cytokines. EC were labeled with 125 I, lysed, immunoprecipitated with mAB 6G10, and electrophoresed on a 10% SDS gel under reducing conditions. Note distinct band at 110 kD at lanes 2-4, which is absent in the control lane. EXAMPLE 5 IL-4 and TNF induce mAb 6G10-recognized expression on bone marrow stromal cells Thirteen years ago, Dr. Michael Dexter and his colleagues (65) established the methodology for maintaining the survival and development of primitive bone marrow stem cells over long periods of time in vitro. This so-called long-term bone marrow culture (LTBMC) system, while initially optimized for the growth of murine cells, has subsequently been modified to support the growth of human bone marrow (66). The essential feature of both systems is the development of an adherent layer of mesenchymal cells derived from the stromal cell population of the bone marrow. The inductive influences provided by the stromal elements of these cultures are essential for the growth and self-renewal and the differentiation of stem cells in these cultures to more specialized progeny (e.g., myeloid progenitors) in a manner which reflects the in vivo situation. Both cytokines released by the stromal cells and adhesive interactions between stromal cells and hemopoietic precursors are important in this process (67, 68). At this point, many of the specific adhesive mechanisms utilized in this in vitro system and its in vivo counterpart are ill-defined. We have discovered that the antigen recognized by mAb 6G10 is expressed on human bone marrow stromal cells in vitro especially after induction with IL-4 and/or TNF. FIG. 11 shows human bone marrow stromal cells grown in long-term marrow culture according to established methods for 2 weeks. In this representative experiment, the cultures were treated for 25 hr with recombinant human TNF-α and IL-4 (10 ng/ml) prior to immunolabeling with mAb 6G10 (20 μg/ml) (panel A), or isotype-matched control antibody (panel B) and goat antimouse IgG-FITC (Southern Biotechnology Assoc.). Immunofluorescence images were recorded using a scanning laser confocal microscope. The IL4/TNFα-enhancement of 6G10-recognized antigen expression on the stromal cells is evident in panel A. This novel finding would not have been predicted a priori from available information about the tissue distribution of VCAM-1. Interestingly, mAb 4B9 (from John Harlan), which also recognizes VCAM-1 on human endothelium, did not bind significantly to human bone marrow stroma cultured in this manner. Therefore, the antigenic epitope recognized by mAb 6G10 may be unique compared to that bound by mAb 4B9. Cell-surface molecules immunoprecipitated with mAb 6G10 from TNFα/IL4-activated cultured human bone marrow stroma differed from that observed on activated omentum EC. The 6G10-recognized molecules were larger in size--one of the species having a molecular weight of 115-130 kD, while the other was larger than 200 kD--as compared to the 100 kD of traditional VCAM-1. Further, we have discovered that a major receptor for VCAM-1, VLA-4 (also known as integrin alpha4/betal (69)), is expressed at high levels on bone marrow cells bearing the CD34 antigen. FIG. 12 shows confirming FACS plots of human CD34 + bone marrow cells stained with negative control mAb (thin line), and anti-VLA-4 mAb 163H (thick line). This finding of coexpression is significant because CD34 expression distinguishes a subset of bone marrow cells (1-4%) which are enriched in primitive stem cells and progenitors (70). Therefore, we infer that adhesive interactions within the bone marrow between hemopoietic stem cells and/or progenitor cells and stromal elements may be mediated by the binding of VLA-4 and the antigen recognized by 6G10. It has been demonstrated in a large animal system (canine) and in man that antibodies directed against two known adhesion molecules, CD44 and LFA-1, respectively (71, 72, 73), administered before or during bone marrow transplantation facilitate the transplantation process in cases where the grafted marrow and recipient are not perfect genetic matches. It follows that mAb 6G10 and its antigen-binding derivatives, as well as other hybridoma-generated or recombinantly engineered binding partners having antigen-binding specificities like mAb 6G10, VCAM-1 and its derivatives, particularly those recognized by mAb 6G10, and VLA-4 and its derivatives are useful either in vitro or in vivo to modify in either a positive or negative fashion the growth or differentiation of bone marrow stem cells or bone marrow stroma. For example, the disclosed cytokines and reagents are useful to facilitate the success of bone marrow transplantation, either by enhancing the growth of the graft (e.g., by IL-4 or TNF-α administration), or by preventing graft versus host disease (e.g., by pretreatment with soluble VCAM-1 receptor recognized by mAb 6G10, or antibodies directed to the VLA-4 receptor recognized by the antigen recognized by mAb 6G10). The disclosed reagents can also be used to immunoselect (e.g., by FACS cell sorting, magnetic bead selection, or negatively by complement lysis) primitive hemopoietic stem cells, progenitor cells, or bone marrow stromal elements. The above-stated applications are particularly useful in cases where the disclosed cytokines are administered either in vivo or in vitro to promote bone marrow transplantation as a curative regimen for neoplastic disease or anemia. The disclosed reagents are readily conjugated to radionuclides or other pharmaceutical moieties to provide targeting devices to achieve high specific localization of the radionuclides or pharmaceutical agents to the bone marrow, for purposes of radioimaging or therapy of neoplastic disease, anemia, or benign hyperplasias of hemopoietic origin. Since IL-4 and TNF-α induce 6G10 antigen expression on bone marrow stroma, the coordinated use of either cytokine in vivo with injection of the aforementioned antibody or receptor conjugates can achieve enhanced specificity of antibody or receptor conjugate localization to the bone marrow. Materials and Methods Endothelial cell cultures. Mesenteric lymph nodes of 0.5- to 7-year-old Macaca nemestrina were obtained through the Tissue Distribution Program of the Regional Primate Research Center at the University of Washington, Seattle, Wash. The lymph nodes were transported in an ice-cold washing solution composed of RPMI-1640 medium buffered with 25 mM HEPES, pH 7.0, and containing tylosin and gentamycin (Sigma). For separation of small blood vessels and endothelial cells, a modification of the method described by Williams (35) was used. Briefly, lymph nodes were cut into pieces and transferred to a digestive solution containing 0.5 mg/ml collagenase Type IV (Sigma), 0.5 mg/ml dispase (Boehringer-Mannheim), and 0.05 mg/ml DNAse (Boehringer-Mannheim) in complete Waymouth medium (WM), pH 7.2, containing 10% heat inactivated fetal bovine serum (FBS, HyClone) and penicillin/streptomycin (GIBCO). The tissue was incubated at 37° C. and agitated by vortexing every 15-20 minutes. Collections of suspended, single cells and small cell aggregates were performed every 0.5-1 hr. Small clumps of cells, fragments of capillaries and larger vessels were separated from the majority of lymphocytes and individual stromal cells by brief centrifugation at 200×G. Pellets were washed in the washing solution and resuspended in either complete WM, or in complete Endothelial Basal Medium (EBM, Clonetics) with 2% FBS, or in serum-free endothelial cell medium CS-1.55 (Cell Systems) with endothelial cell growth supplement (ECGS, 10 μg/ml, Cell Systems) and heparin (50 μg/ml, Cell Systems). Cells were cultured at 370° C. with 5% CO 2 in 25 cm 2 flasks (Falcon) coated previously with 1% gelatin (Sigma) in phosphate buffered saline (PBS), pH 7.0. Approximately 18 hr later, unattached cells were aspirated with fresh medium added. Growing fibroblasts were removed either mechanically with a scraper, or by a 90 sec digestion with 1× trypsin/EDTA (Gibco) on day 5-10. This procedure was repeated every 3-7 days. When endothelial cells grew to confluence, cells were dislodged by a treatment with 1× trypsin/EDTA and passaged at a 1:3 ratio into new flasks. Only cultures in which at least 95% of cells had morphology and markers characteristic of endothelial cells (e.g., uptake of acetylated low density lipoprotein, lack of cytokeratin expression) were used for subsequent experiments. Under these conditions, cells having morphological and immunohistological markers characteristic of monocytic or dendritic cells were rarely seen in the cultures. For adhesion assays, cells from the first two passages were plated at 5×10 3 /well on gelatin-coated 24-well plates (Costar) or uncoated 24-well Primaria™ plates (Falcon) and incubated until they reached confluency, usually for one week. After removing spent medium, 1 ml/well of fresh medium alone or containing a cytokine, either human recombinant IL-1β, IL-2, IL-4 (Immunex), or IFN-γ (Alpha Therapeutic), or a combination of these was added, and cells were grown for an additional 4-72 hrs. Other sources of human recombinant IL-4 and IL-1β include Research & Diagnostic Systems, Minneapolis, Minn. In experiments to test dependency on protein synthesis, emetine (Sigma) was added at a final concentration of 50 μM prior to the adhesion assay. Low density lipoprotein (LDL) uptake. Cells were incubated with acetylated low density lipoprotein labeled with dioctadecyltetramethylindocarbocyanine perchlorate (DiI-Ac-LDL, Biomedical Technologies) at 10 μg/ml for 4 hrs at 37° C. Following 2 washes with PBS, cells were dislodged with trypsin-EDTA, fixed with 2% paraformaldehyde in PBS, and analyzed using 555 nm excitation on a Coulter EPICS 750-2 flow cytometer. A total of 2×10 4 events were collected as list mode files and reprocessed using Reproman™ software (TrueFACS) using forward-angle light scatter to exclude dead cells. Endothelial cells from macaque aorta grown in complete CS-1.55, and human foreskin fibroblasts (a gift from T. Brown, FHCRC), served as positive and negative controls, respectively. Adhesion assays. Peripheral blood lymphocytes (PBL) of Macaca nemestrina were separated from other blood elements by centrifugation on a discontinuous Ficoll gradient as described previously (39). To remove macrophages and other highly adherent leukocytes, cells were incubated in complete WM at 3×10 6 cell/ml on regular tissue culture Petri dishes (Falcon) for 1-2 hrs at 37° C. For adhesion assays, endothelial cells on 24-well plates were washed twice with ice-cold adhesion buffer (HEPES buffered RPMI-1640, pH 6.8, with 1% FBS and 1% glucose); 0.4 ml of adhesion buffer was aliquoted per well; and plates were placed on a gyratory shaker (New Brunswick) at 50 rpm at 4° C. Lymphocytes were collected from Petri dishes, counted, resuspended in ice-cold adhesion buffer at 2.5×10 6 cell/ml, and added to endothelial cell monolayers (0.2 ml/well). After 30 min, cells were fixed by gentle addition of 2% glutaraldehyde in PBS to each well. After two washes with PBS, lymphocyte adhesion was quantified by light microscopy according to the following procedure. For enumeration, each well was divided into four equivalent sectors. Within each sector the number of lymphocytes adhering to endothelial cells was determined for a microscopic field corresponding to 0.24 mm 2 of the well. Results are expressed as a mean±standard deviation. In experiments to test divalent cation dependence, endothelial cells were paraformaldehyde-fixed prior to assay, washed in PBS; and the assays were carried out in PBS with 1% bovine serum albumin, 1% glucose, with and without the addition of Ca ++ (1 mM) or Mg ++ (1 mM). Production of mAb against cytokine-induced endothelial cells. For immunizations of Balb/c mice (Jackson Laboratories), cultured microvascular endothelial cells were activated with IL-4 (10 ng/ml) and IL-1β (1 ng/ml) for 24 hrs, washed with PBS, and dislodged with a scraper. After centrifugation at 200×G, the pellet was resuspended in PBS (0.5 ml/mouse) containing adjuvant peptide, muramyl dipeptide (50 μg/mouse, Sigma), and cells (1-5×10 6 /mouse) were injected into mice subcutaneously (neck region) and intraperitoneally. Four subsequent boasts were conducted over a period of 8 months. Four days after the last boost, the spleen was removed, and lymphocytes were fused with NS-1 myeloma cells using polyethylene glycol (MW-1500, Aldrich) as described by Kennett (40). Selection of hybridomas was accomplished with aminopterin (Sigma). ELISA screening of supernatants was conducted on IL4/IL1-activated versus nonactivated microvascular endothelial cells, after which positive clones were tested in the adhesion assay for their ability to block lymphocyte binding to cytokine-activated endothelial cells. Selected hybridomas were subcloned at least three times. For the production of pure monoclonal antibodies (mAb's), hybridomas were grown in serum-free medium (Nutridoma-NS, Boehringer-Mannheim) and immunoglobulin was precipitated with ammonium sulfate. The hybridoma that produces mAb 6G10 was deposited on Aug. 2, 1990, under accession No. HB 10519 at the American Type Culture Collection (ATCC), 12301 Parklawn Drive, Rockville, Md., U.S.A. Monoclonal and polyclonal antibodies. For blocking lymphocyte adhesion to endothelial cells, all mAb's were added to either endothelial cells or lymphocytes at a final concentration of 10-50 μg/ml or 50% supernatant in the adhesive buffer and incubated for 30 minutes at 37° C. After 2 washes, cells were used in the adhesion assay as described above. For immunofluorescence tests, endothelial cells or CHO cells transfected with cDNAs encoding human VCAM-1, ICAM-1, ELAM-1, or CD4 (gifts of R. Lobb and J. Harlan) were propagated on tissue culture 8-chamber slides (VWR). Live, or ice-cold acetone or paraformaldehyde-fixed (2% in PBS) cells were preblocked with 3% goat serum in PBS, and incubated with mAb or polyclonal antibodies for 2 hr at room temperature. After washes, cells were incubated with FITC-labeled goat anti-mouse Ig antibodies for 30 min at room temperature, washed and mounted for analysis by immunofluorescent microscopy using a Bio-Rad laser scanning confocal microscope and image analysis software. The following antibodies were used: anti-ICAM (RR1/1, a gift from R. Rothlein), anti-LFA-1 (60.3, a gift from P. Beatty), anti-CD44 (Hutch-1), anti-lymph node addressin (MECA-79, a gift of P. Streeter and E. Butcher), anti-class II MHC (HB10a, a gift of E. Clark), anti-factor VIII (Calbiochem), anti-IL-4 (Immunex), and anti-human VCAM-1 (4B9, a gift of J. Harlan; and E1/6, a gift of M. Bevilaqua). In contrast to cultured endothelial cells from macaque aorta, microvascular endothelial cells showed no detectable labeling by polyclonal antibodies to factor VIII, which was in complete agreement with reports of negative labeling with factor-VIII antibodies of cultured microvascular endothelial cells from rat peripheral nodes (36-38). Citations 1. Gallatin, W. M., et al., A cell-surface molecule involved in organ-specific homing of lymphocytes, Nature 304:30, 1983. 2. Holzmann, B., et al., Identification of a murine Peyer's patch-specific lymphocyte homing receptor as an integrin molecule with an α chain homologous to human VLA 4, Cell 56:37, 1989. 3. Duijvestijn, A., and A. Hamann, Mechanisms and regulation of lymphocyte migration, Immunol. Today 10:23, 1988. 4. Gallatin, W. M., et al., Lymphocyte homing receptors, Cell 44:673, 1986. 5. Yednock, T. A., and S. D. Rosen, Lymphocyte homing, Adv. Immunol. 44:313, 1989. 6. Woodruff, J. J., and L. M. Clarke, Specific cell-adhesion mechanisms determining migration pathways of recirculating lymphocytes, Ann. Rev. Immunol. 5:201, 1987. 7. Hamann, A., et al., Evidence for an accessory role of LFA-1 in lymphocyte-high endothelium interaction during homing, J. Immunol. 140:693, 1988. 8. Rothlein, R., et al., A human-intercellular adhesion molecule (ICAM-1) distinct from LFA-1, J. Immunol. 137:1270, 1986. 9. Marlin, S. D., and T. A. Springer, Purified intercellular adhesion molecule-1 (ICAM-1) is a ligand for lymphocyte function-associated antigen-1(LFA-1), Cell 51:813, 1987. 10. Cotran, R. S., New roles for the endothelium in inflammation and immunity, Am. J. Pathol. 129:407, 1987. 11. Jalkanen, S., et al., A distinct endothelial cell recognition system that controls lymphocyte traffic into inflamed synovium, Science 233:556, 1986. 12. Madri, J. A., et al., Matrix-driven cell size change modulates aortic endothelial cell proliferation and sheet migration, Am. J. Pathol. 132:18, 1988. 13. Pals, S. T., et al., Mechanisms of human lymphocyte migration and their role in the pathogenesis of disease, Immunol. Rev. 108:111, 1989. 14. Pober, J. S., Cytokine-mediated activation of vascular endothelium. Physiology and pathology, Am. J. Pathol. 133:426, 1988. 15. Duijvestijn, A. M., et al., Interferon-γ regulates an antigen specific for endothelial cells involved in lymphocyte traffic, Proc. Natl. Acad. Sci. USA 83:9114, 1986. 16. Pohlman, T. H., and J. M. Harlan, Human endothelial cell response to lipopoly-saccharide, interleukin-1, and tumor necrosis factor is regulated by protein synthesis, Cell. Immunol. 119:41, 1989. 17. Bevilaqua, M. P., et al., Interleukin 1 acts on cultured human vascular endothelium to increase the adhesion of polymorphonuclear leukocytes, monocytes, and related leukocyte cell lines, J. Cltn. Invest. 76:2003, 1985. 18. Cavender, D. E., et al., Interleukin 1 increases the binding of human B and T lymphocytes to endothelial cell monolayers, J. Immunol. 136:203, 1986. 19. Bevilacqua, M. P., et al., Identification of an inducible endothelial-leucocyte adhesion molecule, Proc. Nati. Acad. Sci. USA 84:9238, 1987. 20. Yu, C. L., et al., Human gamma interferon increases the binding of T lymphocytes to endothelial cells, Clin. Exp. Immunol. 62:554, 1985. 21. Yu, C. L., et al., Effects of bacterial lipopolysaceharide on the binding of lymphocytes to endothelial cell monolayers, J. Immunol. 136:569, 1986. 22. Cavender, D. E., et al., Stimulation of endothelial cell binding of lymphocytes by tumor nectosis factor, J. Immunol. 139:1855, 1987. 23. Issekutz, T. B., and J. M. Stoltz, Stimulation of lymphocyte migration by endotoxin, tumor necrosis factor, and interferon, Cell. Immunol. 120:165, 1989. 24. Issekutz, T. B., Effects of six different cytokines on lymphocyte adherence to microvascular endothelium and in vivo lymphocyte migration in the rat, J. Immunol. 144:2140, 1990. 25. Kalaaji, A. N., et al., Enhancement of lymphocyte localization in skin sites of sheep by tumor necrosis factor alpha, Immunol. Letters 23:143-148, 1989. 26. Stoolman, L. M, Adhesion molecules controlling lymphocyte migration, Cell 56:907, 1989. 27. Dustin, M. L., and T. S. Springer, Lymphocyte function-associated antigen-1 (LFA-1) interaction with intercellular adhesion molecule-1 (ICAM-1) is one of at least three mechanisms for lymphocyte adhesion to cultured endothelial cells, J. Cell Biol. 107:321, 1988. 28. Price, G. E., and M. P. Bevilaqua, An inducible endothelial cell surface glycoprotein mediates melanoma adhesion, Science 246:1303, 1989. 29. Osborn, L., et al., Direct cloning of vascular cell adhesion molecule 1, a cytokine-induced endothelial protein that binds to lymphocytes, Cell 59:1203, 1989. 30. ElIces, M. J., et al., VCAM-1 on activated endothelium interacts with the leucocyte integrin VLA-4 at a site distinct from the VLA-4/fibronectin binding site, Cell 60:577, 1990. 31. Streeter, P. R., et al., Immunohistologic and functional characterization of vascular addressin involved in lymphocyte homing into peripheral lymph nodes, J. Cell Biol. 107:1853, 1988. 32. Streeter, P. R., et al., A tissue-specific endothelial cell molecule involved in lymphocyte homing, Nature (Lond.) 331:41, 1988. 33. Sarvetnick, N., et al., Insulin-dependent diabetes mellitus induced in transgenic mice by ectopic expression of class II MHC and interferongamma, Cell 52:773, 1988. 34. Hendriks, H. R., et al., Rapid decrease in lymphocyte adherence to high endothelial venules in lymph nodes deprived of afferent lymphatic vessels, Eur. J. Immunol. 17:1691, 1987. 35. Williams, S. K., Isolation and Culture of Microvessel and Large-Vessel Endothelial Cells; Their Use in Transport and Clinical Studies, in Macrovascular Perfusion and Transport in Health and Disease, McDonagh, ed.; Karger, Basel, p. 204, 1987. 36. Kumar, S., et al., Heterogeneity in endothelial cells from large vessels and microvessels, Differentiation 36:57, 1987. 37. Ager, A., Isolation and culture of high endothelial cells from rat lymph nodes, J. Cell Sci. 87:133, 1987. 38. Ise, Y., et al., Molecular mechanisms underlying lymphocyte recirculation. I. Functional, phenotypical and morphological characterization of high endothelial cells cultured in vitro, Eur. J. Immunol. 18:1235, 1988. 39. Gallatin, W. M., et al., Selective replication of simian immunodeficiency virus in a subset of CD4+ lymphocytes, Proc. Natl. Acad. Sci. USA 86:3301, 1989. 40. Kennett, R. H., Fusion Protocols. Fusion by Centrifugation of Cell Suspended in Polyethylene Glycol, in Monoclonal Antibodies. Hybridomas: a New Dimension in Biological Analysis, R. H. Kennett et al., eds.; Plenum Press, New York, p. 365, 1980. 41. Monroe, J. G., et al., Lymphokine regulation of inflammatory process: interleukin-4 stimulates fibroblast proliferation, Clin. Immunol. Immunopathol. 49:292, 1988. 42. Park, L., et al., Characterization of the human B cell stimulatory factor 1 receptor, J. Exp. Med. 166:476, 1987. 43. Park, L. S., et al., Characterization of the high-affinity cell-surface receptor for murine B-cell-stimulating factor 1, Proc. Nati. Acad. Sci. USA 84:1669, 1987. 44. Lowenthal, J. W., et al., Expression of high affinity receptors for murine interleukin 4 (BSF-1) on hemopoietic and nonhemopoietic cells, J. Immunol. 140:456, 1988. 45. Elias, J. A., et al., A synergistic interaction of IL-6 and IL-1 mediates the thymocyte-stimulating activity produced by recombinant IL-1-stimulated fibroblasts, J. Immunol. 142:509, 1989. 46. Broxmeyer, H. E., et al., Synergistic effects of purified human and murine B cell growth factor 1/IL-4 on colony formation in vitro by hemopoietic progenitor cells, J. Immunol. 141:3852, 1988. 47. Makgoba, M. W., et al., Functional evidence that intercellular adhesion molecule-1 (ICAM-1) is a ligand for LFA-1-dependent adhesion in T cell-mediated cytotoxicity, Eur. J. Immunol. 18:637, 1988. 48. Pober, J. S., et al., Ia expression by vascular endothelium is inducible by activated T cells and by human γ-interferon, J. Exp. Med. 167:1339, 1983. 49. Collins, T., et al., Recombinant human tumor necrosis factor increases mRNA levels and surface expression of HLA-A,B antigens in vascular endothelial cells and dermel fibroblasts in vitro, Proc. Nati. Acad. Sci. USA 83:446, 1986. 50. Lapiere, L. A., et al., Three distinct classes of regulatory cytokines control endothelial cell MHC antigen expression, J. Exp. Med. 167:794, 1988. 51. Gimbrone, M. A., Jr., et al., Endothelial interleukin-8: a novel inhibitor of leukocyte-endothelial interactions, Science 246:1601, 1989. 52. Thornhill, M. H., et al., IL-4 increases human cell adhesiveness for T cells but not for neutrophils, J. Immunol. 144:3060, 1990. 53. Issekutz, T. B., et al., Role of interferon in lymphocyte recruitment into the skin, Cell. Immunol. 99:322, 1986. 54. Issekutz, T. B., et al., Lymphocyte recruitment in delayed-type hypersensitivity. The role of gamma-interferon, J. Immunol. 140:2989, 1988. 55. Hughes, C. C. W., et al., Adhesion of lymphocytes to cerebral microvascular cells: effects of interferon-γ, tumor necrosis factor and interleukin-1, Immunology 64:677, 1986. 56. Oppemheimer-Marks, N., and M. Ziff, Migration of lymphocytes through endothelial cell monolayers: augmentation by interferon-.sub.γ, Cell. Immunol. 114:307, 1988. 57. Damle, N. K., and L. V. Doyle, Ability of human T lymphocytes to adhere to vascular endothelial cells and augment endothelial permeability to macromolecules is linked to their state of post-thymic maturation, J. Immunol. 144:1233, 1990. 58. Paul, W. E., and J. Ohara, B-cell stimulatory factor 1/interleukin 4, Ann. Rev. Immunol. 5:429, 1987. 59. Noelle, R., et al., Increased expression of Ia antigens on resting B cells: an additional role for B-cell growth factor, Proc. Natl. Acad. Sci. USA 91:6149, 1984. 60. McHeyzer-Williams, M. G., Combinations of interleukins 2, 4 and 5 regulate the secretion of murine immunoglobulin isotypes, Eur. J. Immunol. 19:2025, 1989. 61. Tsuji, K., et al., Synergistic action of phorbol ester and IL-3 in the induction of "connective tissue-type" mast cell proliferation, J. Immunol. 144:678, 1990. 62. Wankowicz, Z., et al., Synergy between tumor necrosis factor alpha and interleukin-1 in the induction of polymorphonuclear leukocyte migration during inflammation, J. Leukoc. Biol. 43:349, 1988. 63. Rabin, E. M., et al., Interferon-γ inhibits the action of B cell stimulatory factor (BSF)-1 on resting B cells, J. Immunol. 137:1573, 1986. 64. Vercelli, D., et al., IL-4 inhibits the synthesis of IFN-gamma and induces the synthesis of IgE in human mixed lymphocyte cultures, J. Immunol. 144:570, 1990. 65. Dexter, T. M. et al., J. Cell. Physiol. 91:335-344, 1977. 66. Gartner, S. M., and H. S. Kaplan, Proc. Natl. Acad. Sci. USA 77:4756-4761, 1980. 67. Roberts, R. A. et al., Nature 326:403-405, 1987. 68. Bentley, S. A., Exp. Hematol. 9:303-312, 1981. 69. Elices, M. J. et al., Cell 60:577, 1990. 70. Civin, C. I. et al., J. Immunol. 133:157-162, 1984. 71. Schuening, F. et al., Transplantation 44:607, 1987. 72. Sandmaier, B. M., Storb, R., Appelbaum, F. R., Gallatin, W. M. (1990) Blood, in press. 73. Fischer, A. et al., Transplantation 3:204, 1988. While the present invention has been described in conjunction with a preferred embodiment, one of ordinary skill in the art after reading the foregoing specification will be able to effect various changes, substitutions of equivalents, and alterations to the subject matter set forth herein. It is therefore intended that the protection granted by Letters Patent hereon be limited only by the definitions contained in the appended claims and equivalents thereof.
A therapeutic method of modulating the immune response, by administering to a patient an amount of IL-4 effective to promote peripheral blood lymphocyte adhesion to microvascular endothelial cells in lymphoid organs. The IL-4 is preferably coadministered with IL-1β. An improved method of screening a cell line for the production of a binding partner that binds with a cell adhesion molecule, by contacting the binding partner with IL4-activated and nonactivated microvascular endothelial cells, and selecting binding partners that bind to the IL4-activated microvascular endothelial cells but not to the nonactivated microvascular endothelial cells. The selected binding partners may thereafter be tested for the ability to block lymphocyte binding to cytokine-activated endothelial cells. The binding partners are preferably also characterized by binding to human VCAM-1 and to IL4- or TNFα-activated bone marrow stromal cells. A representative embodiment is mAb 6G10 produced by hybridoma ATTC No. HB 10519. A therapeutic method of modulating the immune response in a patient, by administering to the patient an agent that specifically binds to IL4-activated microvascular endothelial cells, in an amount effective to impede transmigration of lymphocytes that specifically bind to VCAM-1 from blood across postcapillary venules.
2
BACKGROUND OF THE INVENTION This invention relates to the development of a metal-jacketed, non-hollow point bullet intended for law enforcement use which exhibits optimum penetration and more reliable and consistent expansion than hollow point bullets when fired through dry materials such as wallboard, plywood and heavy clothing, while maintaining 100% weight retention. In December of 1988, the Federal Bureau of Investigation Academy Firearms Training Unit designed and implemented a special test protocol for evaluating the effectiveness of modern ammunition using various types of bullets. Each cartridge and bullet type submitted for testing was used in eight different Test Events. All of the tests ultimately entailed the penetration of blocks of 10% ballistic gelatin, with and without intermediate barriers in front of the gelatin. These tests included firing bullets into bare gelatin at a distance of 10 feet and through the following materials placed in front of the gelatin; heavy clothing, sheet steel, wallboard (gypsum board), plywood, automobile glass, heavy clothing at 20 yards, and automobile glass at 20 yards. The FBI does not have a specific requirement for bullet expansion. The criterion is the volume of the wound. However, wound volume is a direct result of the rate and extent of bullet expansion. That volume is measured as the product of the extent of penetration and the frusto area resulting from the expansion. They grade sample ammunition, and the wound volume is one of the parameters used in reaching a purchasing decision. Ammunition with less than twelve (12) inches of penetration is usually not purchased. Penetration beyond eighteen (18) inches is not utilized in calculating the wound volume. The FBI protocol is the most stringent test protocol ever devised. Many of the ammunition manufacturers soon discovered that the hollow point bullets, which they had at that time, produced very poor results in gelatin after passing through dry barriers. In an attempt to increase the robustness of their bullets, manufacturers developed bullet-weakening features to enhance post-dry-barrier expansion. These efforts were met with minimal success because ultimately, performance was still severely limited by the hollow point concept itself. Even today, many of the best hollow point bullets available perform only marginally well when tested using the FBI protocol. Hollow point bullets rely on simple hydraulic action to initiate radial expansion. This hydraulic action occurs as fluid enters and fills the bullet's nose cavity upon impact with a fluid-based target. Because of its dependence on fluid and the actual filling of its nose cavity with fluid, a hollow point bullet expands poorly, if at all, when impacting dry, intermediate targets such as wallboard, plywood and heavy fabric. In short, without the immediate presence of fluid, the Hollow point bullet's nose cavity will clog severely after encountering almost any dry media. The material producing the worst effect on hollow point bullet performance is wallboard. This is because the gypsum dust has a tendency to pack tightly into the nose cavity which essentially transforms the bullet into a solid-nosed projectile which will, at best, exhibit minimal expansion due to the inherent strength of the core metal comprising its cavity wall. Essentially, when a dry media is substituted for fluid in its cavity, the hollow point bullet is unable to take advantage of simple hydraulics. By utilizing a completely different expansion technology, the bullet described hereinafter overcomes the inherent limitations of hollow point bullets. BRIEF SUMMARY OF THE INVENTION The design of our bullet is characterized by a collapsible nose portion. This type of bullet provides a limited but adequate degree of expansion while penetrating to the degree demanded by the FBI. While doing so, it retains substantially 100% of its weight. The above bullet is comprised of a jacket of malleable metal, such as one formed predominantly of copper, and has a closed conventionally tapered nose portion and rearward cylindrically shaped side wall which are preferably open at their rear end. The nose portions have circumferentially spaced weakened areas, which extend axially of its nose-defining wall are preferably formed by deep internal scoring, although external scoring may be utilized. Compressed within the closed forward end of the jacket and bearing against the interior surface thereof is a soft rubber core, the rear portion of which terminates at, ahead of, or rearward of the inflection point. This inflection point is located at the juncture of the tapered nose portion and the forward end portion of the cylindrical wall of the jacket. Mounted within the cylindrical wall of the jacket is a metal core which bears against the rear end of the rubber core in compressing relation thereto. Preferably, the rear end of the metal core terminates adjacent the rear end of the cylindrical wall of the jacket, and the terminal portions of said wall thereat are crimped inwardly to lock the metal core therewithin in compressing relation to the rubber core. The forward end surface of the metal core is preferably recessed with a concave or dished out configuration. The metal core is preferably made of pure lead or some other metal which is softer than the metal of which the jacket is made. When the above-described bullet strikes and penetrates a target which is of soft to medium-hardness, the nose portion collapses axially, which increases the pressure upon the rubber core. This causes the latter to rupture the nosedefining portions at the scored or otherwise weakened areas, and to separate along the scoring lines. As this occurs, the metal of the nose portion and the rubber core expand substantially in a radial direction, while the cylindrical wall and the metal core therewithin remain directly therebehind and retain substantially 100% of their weight. The above bullet will penetrate such materials at least twelve (12) inches and the nose portion will expand radially in excess of 50%, while retaining its weight at approximately 100%. Actual measurements show the radial expansion as great as 70%. Both the metal core and the rubber core will remain encapsulated by the metal jacket. Our bullet will penetrate ten (10) layers of heavy denim cloth and still expand adequately in 10% ballistic gelatin. No conventional hollow-point bullet extant can duplicate or exceed this type of performance. The front core may be comprised of EP Rubber (EPDM) which is Ethylene Propylene and is the preferred material from which that core may be made. Other suitable materials include silicone, synthetic rubber, and natural rubber. The rear core is preferably formed of a metal which is softer than that from which the jacket is made. Pure lead is the preferred material. Other suitable metals are lead alloy, zinc or tin. The bullet ogive can be frusto-conical in shape or it may comprise a curving ogive. It is a general object of our invention to provide a captive soft-point bullet which will overcome the disadvantages of a hollow-point bullet and will thereby out-perform all extant hollow or soft-point bullets with respect to uniform, reliable expansion and adequate penetration when fired into soft to medium-hard targets after first having passed through dry intermediate barriers such as wallboard or heavy clothing. A further object is to provide a captive soft-point bullet which will expand radially to a relatively large diameter when fired into soft to medium-hard targets and still penetrate to a depth of at least twelve (12) inches. Another object is to provide a captive soft-point bullet which when fired into soft to medium-hard targets will penetrate to at least twelve (12) inches while expanding radially to at least a 50-70% extent. A still further object is to provide a captive soft-point bullet which provides 100% weight retention after first passing through intermediate barriers and thereafter impacting a soft to medium-hard target. BRIEF DESCRIPTION OF THE DRAWINGS These and other objects and advantages of the invention will more fully appear from the following description, made in connection with the accompanying drawings, wherein like reference characters refer to the same or similar parts throughout the several views, and in which: FIG. 1 is a perspective view of the bullet jacket incorporated in the invention; FIG. 2 is a side elevational view of the jacket shown in FIG. 1 prior to seating of the rubber core therein, with a nose portion and a portion of the cylindrical wall broken away and shown in vertical section; FIG. 3 is a side elevational view of the preferred form of the invention in its final form; FIG. 4 is a side elevational view of the bullet shown in FIG. 3, with a portion of the cylindrical side wall broken away and a portion shown in vertical section and showing the thin web radially opposite and outside of the internal score; FIG. 5 is a side elevational view of a modified version of the bullet in which portions are broken away to show the nose portion in section, the forward end of the metal core is concaved and the rubber core extends rearwardly to a point behind the inflection point; FIG. 6 is a perspective view of our preferred bullet after it has struck and penetrated a target which included a back-up consisting of a block of 10% gelatin; FIG. 7 is a side elevational view of our bullet with the near wall of the jacket broken away to show the interior in longitudinal section and with the rubber core extending rearwardly and terminating ahead of the inflection point; FIG. 8 is a vertical sectional view, with portions shown in elevation, of a similar jacket in which the scoring is external. DETAILED DESCRIPTION OF THE INVENTION As described above, a number of variations of our invention are shown in FIGS. 1-8, inclusive. The jackets which are shown are all made of the same or similar material, and the forward end of the scoring may start at the closed end of the bullet or rearward thereof, and may terminate ahead of, at, or rearwardly of the inflection point which is at the rear end of the nose-defining portions. Very narrow slits may be utilized in lieu of or in combination with the scoring. Basically, the narrow slits or the scoring constitute weakened areas of the nose portion of the bullet. As shown in FIG. 2, the jacket 10 as shown, has cylindrical wall 11 which taper inwardly in nose-defining wall 12 which in turn terminate in a flat solid end plate 13 . Internal scoring 14 extends rearwardly from the flat nose end plate 13 and terminates ahead of the inflection point 15 . The scoring 14 which we utilize is deep, so as to leave only a very thin web 16 directly opposite and outwardly of the valley made by the scoring. In FIG. 4, as shown, the nose-defining wall 12 of the jacket 10 encapsulate a rubber core 17 which occupies the nose portion behind the end plate 13 , and extend rearwardly beyond to the inflection point 15 . The scores 14 extend rearwardly to the inflection point 15 . Disposed immediately behind the rubber core 17 is a soft metal core 18 which fills the entire cavity of the cylindrical wall 11 from the rear end 19 thereof to the rear end of the rubber core 17 . As described hereinafter, the metal core 18 in each of the variations shown herein is disposed tightly across and against the rear end of the rubber core 17 so as to urge the same against the inner surface of the end plate 13 and against the interior surface of the nose-defining portions 12 . As shown, the flat forward end 20 of the soft metal core engages and is compressed against the rear surface of the rubber core. The jacket 10 is substantially the same in FIG. 5 as that shown in FIG. 4, except that the scoring 22 extends rearwardly from the inner surface of the nose plate 13 and terminates rearwardly of the inflection point 15 . The forward surface 24 of the rubber core 21 is compressed against the inner surface of the nose plate 13 by the concave forward end 25 of the metal core 23 which terminates at and bears against the rear surface of the rubber core 21 . The bullet shown in FIG. 5 is the preferred form of our invention. It will be noted that the forward end of the metal core 23 is generally concaved or dished out to a depth of about 0.150″ to 0.300″, and the cavity thereof is filled with the rear end portion of the rubber core 21 . We have found that this combination facilitates the expansion of the nose-defining portions and the rubber core 21 . As shown at the rear end of the bullet 10 , the rear end portions 11 a of the cylindrical wall 11 are crimped inwardly around the rear end of the soft metal core 23 to effectively hold the metal core 23 in pressure-bearing relation against the rubber core 21 . The rear end of the metal core 23 is locked within the jacket 10 by the crimped rear end portions 11 a of the cylindrical wall 11 . As shown, the crimped portions 11 a are embedded by the swaging actions utilized in forming the bullet, after the rubber and soft metal cores have been positioned as shown. FIG. 6 shows one of our bullets after it has been fired through a soft to medium hard target and penetrated through 10% gelatin a distance of approximately twelve (12) inches. It can be seen that the jacket 11 retained the metal core and the rubber core completely encapsulated. The nose portion is collapsed entirely, with the split jacket sections 30 thereof widely separated and showing the axially collapsed and radially expanded sections 31 of the rubber core visible therebetween in confined relation. The flat end plate remains intact in support of the expanded sections 30 and 31 . As a consequence, the bullet has retained 100% of its original weight. FIG. 7 shows another form of our invention in which the scoring is located in a slightly different position. The portions of the jacket which are the same as those shown in the other views are identified by the same numerals wherever they are the same or highly similar in construction. FIG. 7 shows scoring 27 which extends rearwardly to a point forward of the inflection point 15 . Since it is deep, as is the case in each of the bullets shown herein, such deep scoring leaves only a very thin web 28 , which is disposed radially outwardly and directly opposite the bottom of the individual scores. It will be seen that the scores 27 originate at or near the inner surface of the nose or end plate 13 . As is also shown, the rear end surface of the rubber core 26 terminates forwardly of the inflection point 15 . The flat forward end of the soft metal core 29 , bears against the rear end surface of the rubber core 26 and compresses the same tightly against the inner surface of the nose plate 13 and the nose defining portions 12 , as well as the web 28 . FIG. 8 shows a bullet similar to that shown in FIG. 7 except that the scoring is external, instead of internal. In view thereof, the elements of FIG. 8 are identified with some of the same numerals as those shown in FIG. 7, with the exception of the external scoring 32 and the web 33 created thereby, in lieu of the outwardly disposed web 28 of FIG. 7 . The length of the scoring is the same, as is the depth thereof. If desired, a retaining disc 34 may be secured behind the metal core by the inwardly crimped rear end 35 of the sidewalls 36 , but we have found this disc to be non-essential. The jacket thickness can vary substantially, since the captive soft-point bullet described herein may be used for low velocity pistol applications, high velocity pistol applications, and certain rifle applications. The latter have very high velocity characteristics. For pistol bullets, the thickness range of the jacket is approximately 0.007″ to 0.040″. For rifle bullets, the usable range would be approximately between 0.010″-0.090″. It should be noted that although the jacket wall may be uniform originally in thickness, there is a substantial degree of wall taper in most pistol and rifle jackets which may be utilized in the formation of the jacket of our bullet. An example of the above is a typical pistol jacket which may have a thickness of 0.015″ near the radius of its closed end plate and a jacket wall thickness of 0.009″ at its open mouth end. The jackets shown herein are comprised of copper or a gilding metal. These are the most common (and popular) jacket materials used in the industry. A mild steel jacket, if thin enough and malleable enough might be another alternative. Gilding metal is a commonly used term of the art and is comprised of a copper-zinc alloy commonly used for bullet jackets. Gilding metal usually contains either 95% copper and 5% zinc or 90% copper and 10% zinc. The range of copper content is about 80% to 95%. The more zinc, the harder and less malleable will be a jacket formed thereof. In arriving at our invention, we were looking for “relatively large” expansion and “adequate” (sufficient) penetration. When a bullet achieves deep penetration, it is usually at the cost of expansion, in that the bullet fails to expand to a sufficiently large diameter. The opposite is equally true—if the bullet expands to a large degree, penetration is compromised. The captive soft-point bullet which we have developed, along with all others, remains locked into certain terminal ballistic parameters. However, our captive soft-point bullet produces “relatively large expanded diameters” and “adequate penetration” in soft to medium-hard targets. The forward nose or end plate 13 of our bullet is solid and closed. As a consequence, both the rubber and soft metal cores are encapsulated by the jacket upon and after impact, since the nose plate is flat and closed. The optimum number of scores appears to be six (6). The number of scores may be either even or odd. We have found that with three (3) scores the expansion is somewhat limited, due to the additional strength provided by the extra width of the individual jacket sections 30 . A greater velocity of approximately fourteen hundred (1400) feet per second or more is required to sufficiently expand such a bullet with only three (3) scores. The greater the depth of the scores the weaker the bullet nose and thus, the more rapidly it expands on impact. The greater the length of the scores, the weaker the bullet will be and the more rapidly it will expand on impact. Score length also regulates the diameter of expansion since the longer the scores, the larger the expansion. The external scores, like the internal scores, can commence at or near the nose of the jacket and terminate forward of, at, or behind the inflection point 15 . Like the internal scores, the external scores extend longitudinally of the nose-defining portions 12 and their length can be varied similarly. The depth of the external scores is similar in depth to that of the internal scores and as a consequence, the thickness of the web, which is left after the scoring is accomplished, is substantially the same as that resulting from the internal scoring. If desired, both the internal and external scoring can be made to such a depth that the thickness of the web approaches zero or, as a further alternative, a very narrow slit may be formed. Wherever hereinafter reference is made to the webs, it is intended to include a very narrow slit as an alternative for the web. The pistol bullets described above have been tested by firing the same through various layers of denim. The greatest number of denim layers in any Federal Government Test Protocol is four (4). Our tests show that an expanding pistol bullet, made in accordance with the above, will expand markedly while passing through ten (10) layers of denim and yet will provide adequate penetration as it enters 10% back-up gelatin. There is no extant pistol bullet which will match this performance. The rubber core of the above bullets expands while penetrating the denim layers to a very substantial extent, prior to contacting the gelatin target which is disposed immediately behind the various layers of denim. The expansion occurs very rapidly in the denim and the bullet continues expanding in the gelatin. During the initial stages of our development of the above bullet, upon impact and depending on the degree of inertia generated, the rear core would sometimes slide forward within the jacket. However, recent prototypes have been developed to a point where we have nearly eliminated all forward relative movement of the rear core at impact. Thus, the rear end portions of the rear core remain relatively flush with the base of the bullet. We have found that if the front portion of the metal core 23 is concaved, as shown in FIG. 5, the front portion of the soft metal core 23 will expand and stretch the jacket material behind the inflection point 15 . This adds to the overall expanded diameter of the bullet as it reaches its maximum penetration. It should be understood that upon impact, the scores allow the nose portion of the jacket to split. Immediately thereafter, the nose-defining portions commence to collapse axially and in doing so, the bullet expands radially. In doing so, the jacket material behind the inflection point may stretch and tear. These tears originate from the rearmost terminus of each score. In essence, they become in-line extensions of the scores and travel into the unscored area of the jacket. The additional “split length” in the unscored area adds to the diameter of the expanded bullet. As shown in FIGS. 1-4, 7 and 8 , the forward end of the metal core of our bullet may have a flat solid forward portion, or, as shown in FIG. 5, it can contain a hollow-forward portion. The shape and size of the hollow point may vary. It may appear as shown in FIG. 5 or it may have a deeper cavity or a cavity comprising a compound angle. FIG. 5 depicts the recess as being merely concave in form. The actual rubber core may have a length within the range of 0.050″-0.350″. We have found that a web having a thickness of 0.002″ is very effective. Webs which measure less than 25% of the jacket wall will function adequately at handgun velocities. The preferred thickness of the web approximates 20% of the jacket wall thickness, but it may be reduced to zero. The preferred thickness of the cylindrical wall is 0.011″. It will be seen by reference to the drawings that the front end 13 of the nose portion is thicker than the side wall of said portions and exceeds the thickness of the cylindrical wall slightly. This is a natural result of the forming of the jacket from a conventional bullet jacket having one closed end and the other end being open. The bullets described hereinabove, as shown in the drawings hereof, have been found to be highly effective, particularly for law enforcement purposes. In law enforcement operations, a bullet frequently must pass through soft to medium-hard materials before engaging the true (ultimate) target, and thereafter penetrate the body of the true (ultimate) target. This ultimate target will frequently involve at least one or more layers of clothing, before entering the flesh of the ultimate target which is relatively soft, much like 10% gelatin. Frequently, bones are encountered by the bullet and for that reason, substantial penetration is desired. Also, the expanded bullet conveys substantial shock. The bullets shown and described hereinabove have been found to be unusually effective for such law enforcement purposes. As indicated above, these bullets will penetrate as many as ten (10) layers of denim, and still sufficiently penetrate the target therebehind, while continuing to expand a substantial distance radially to provide substantial shock and wound volume to the ultimate target. As indicated above, we have found that these bullets will expand radially as much as 50-70% and yet penetrate to a distance of approximately 12″ or more. For these reasons, these bullets for use against soft to medium-hard targets are much more effective than any extant bullet. It will, of course, be understood that various changes may be made in the form, details, arrangement and proportions of the parts without departing from the scope of the invention which comprises the matter shown and described herein and set forth in the appended claims.
A bullet comprised of a jacket of malleable metal having a closed nose portion encapsulating a forward core made of rubber, the nose portion having circumferentially spaced, axially extending deep scores in its nose-defining walls, and a rear core within the jacket made of a malleable metal preferably softer than that of the jacket and hard-seated against the rear of the rubber core to bring pressure against the interior surface of the meplat and the interior surface of the nose-defining walls of the nose portion, whereby upon the bullet striking and penetrating a target, the scores will rupture and the nose-defining walls of the nose portion will collapse axially and open, and together with the rubber core, will expand substantially in a radial direction to thereby provide an adequate penetration, optimum expansion bullet.
5
BACKGROUND OF THE INVENTION The present invention relates to an automatic liquid control system for an automatic clothes washing machine. More particularly, the invention relates to a system for achieving an optimum liquid level in the clothes washing machine by detecting the clothes load height and the speed of agitation. The amount of washing liquid required in an automatic washer for achieving an optimum washing operation is dependent on the clothes load quantity and the desired wash cycle or agitator speed. For example, if a large clothes load is disposed in the washer, the amount of washing liquid supplied to the automatic washer must be of a quantity to adequately wash the clothes without undue clothes wear. For a quantity of clothes, if the agitation rate is high, indicating a wash cycle for sturdy clothes, the wash liquid supplied to the washer may be less than the quantity of wash liquid supplied when the selected agitation rate is low, indicating a delicate load. Additionally, at lower speeds, some loads require extra water for roll-over and less wear. Accurate clothes load quantity and agitator speed information is necessary, therefore, to determine optimum washing liquid volume. Typically, the clothes load quantity in an automatic washer is visually determined by the user who then manually selects between several predetermined washing liquid quantities using a manually adjustable liquid level switch. Various systems have also been developed for automatically determining the clothes load quantity in an automatic washer such that an optimum quantity of washing liquid may be provided. U.S. Pat. No. 5,042,276 discloses a clothes detection means utilizing the inertia of the clothes load for determining the clothes load quantity. A motor is repeatedly energized for rotating an agitator and the clothes load disposed in a wash basket. Between each energization, a pause occurs during which the power supply to the motor is turned off while the speed of the inertial rotation of the agitator is measured to detect the clothes load quantity. The inertial rotation is measured by monitoring the back electromagnetic force created in the motor during the pause. The washing liquid level is then determined from the amount of clothes detected. In U.S. Pat. No. 4,480,449, an automatic liquid level control is provided which measures the volume of liquid required to be added to a tub to increase the liquid level in the tub by a predetermined increment. The measured amount is compared to a reference amount corresponding to an empty tub. When the measured amount equals the reference amount, the clothes in the washer will be covered and the control terminates introduction of washing liquid into the tub. The above described methods, however, are relatively costly and complex. It would be advantageous therefore, to develop a system which is relatively less expensive and less complex. Furthermore, it would be advantageous to develop a washing liquid fill system which could accurately determine the clothes load quantity and also account for any significant deviation in clothes load height within the wash basket such as may occur if a pillow or the like is placed in the wash basket. Further, it would be an improvement if such a system would receive an input representative of the selected agitator speed for modifying the water level such that an optimum water level would be provided. In the present invention, the inventors contemplate a cloth detection system for an automatic washer utilizing ultrasonic distance measuring system for measuring the quantity of clothes in the wash basket. The agitator speed is a user selectable input, which may be controlled through a control panel provided on the console of the washer. No prior art teaches or suggests the use of ultrasonic distance measuring systems in an automatic washer for measuring the clothes heights prior to the addition of wash liquid, much less a system receiving a clothes height input and an agitator speed input for determining an optimum quantity of wash liquid. Ultrasonic distance measuring systems for monitoring the fill level in tanks, however, are well known. Typically, in these systems, an electroacoustic transducer may be controlled such that it is used alternately as a transmission transducer and as a reception transducer. The electroacoustic transducer is preferably arranged in a container above the highest possible fill level in such a manner that the sonic or ultrasonic pulses transmitted by the transducer strike the surface of the material in the container and the echo pulses reflected at the surface of the material are sent back to the transducer. The excitation of the transducer is by electrical excitation pulses with the frequency of the sonic or ultrasonic wave. The electrical excitation pulses are generated by a pulse generator and applied via a transmission/reception switch to the transducer. The electrical reception signal generated by the transducer in response to the received echo signals are applied via the transmission/reception switch to a processing circuit which determines therefrom the time interval between the instants of transmission of a transmission pulse and the reception of an echo pulse originating from the transmission pulse. This time interval corresponds to the travel time of the ultrasonic wave in the container and is thus an indication of the filling level in the container. U.S. Pat. Nos. 4,972,386, 4,675,854, and 4,437,497, are all examples of ultrasonic systems for monitoring the fill level within a tank which operate substantially similar to the system described above. None on these patents, however, teach or suggest a system for determining the optimum fill level and then controlling the filling of the tank to the determined optimum fill level. Rather, the systems disclosed in these patents all simply monitor the fill level. Ultrasonic range finding systems are also well known for use in an ultrasonic range finder camera. U.S. Pat. Nos. 4,439,846, 3,522,764 and 4,199,246 all disclose the use of a sonic range-finder systems in a camera which transmit a burst of sonic energy toward a subject and receives an echo pulse from the subject for determining distance from the transmitter/receiver and the subject. Furthermore, detailed schematic circuit diagrams are shown, in these references, for controlling the ultrasonic transducer utilized within the range finding systems. From a review of the above described background information, it would therefore appear to be an improvement in the art if a less expensive, more versatile and more accurate system was provided for determining the clothes load quantity in an automatic washer. More particularly, it would be an advancement in the art if a washing liquid level system were provided for achieving an optimum wash liquid level by based on the clothes load height and the selected agitator speed. SUMMARY OF THE INVENTION Accordingly, a primary object of the present invention is to provide an automatic system for determining the optimum quantity of washing liquid in an automatic washer. More specifically, it is an object of the present invention to utilize an ultrasonic distance measuring system for determining clothes load height in a wash basket and from that information in combination with an input representative of the agitator speed determining an optimum washing liquid quantity. Another object of the present invention is to utilize a control device which performs a fuzzy control operation for controlling the wash liquid level on the basis of a signal representative of the clothes height and a signal representative of the agitator speed. According to the present invention, the foregoing and other objects are attained by an automatic washing machine having an automatic washing liquid level control system including an ultrasonic apparatus for detecting the height of the clothes load added to the washing machine and generating a signal representative of the clothes height, a control panel means for allowing user selection of the agitator speed and means for generating a signal representative of the desired agitator speed. A control unit is provided including a fuzzy control which performs fuzzy inference on the basis of the signal representative of the clothes height and the signal representative of the agitator speed such that the optimum washing liquid level is achieved. In particular, membership functions according to fuzzy theory are defined for the clothes height and the agitator speed. Rules are defined for the height and agitator speed conditions such as for very high clothes height and low agitator speed, or medium high clothes height and high agitator speed, and so on. Each rule is executed using the fuzzy theory to thereby achieve an optimum washing liquid level. The automatic washer includes a vertical axis tub disposed within a cabinet and further having a rotatable perforate wash basket disposed within the tub for receiving a load of clothes and a quantity of washing liquid. The cabinet includes an openable lid disposed above the tub and the wash basket. A transducer is provided, mounted in the cabinet lid, for operating in a first mode as a transmitter for transmitting a sonic energy pulse and directing the sonic energy pulse into the wash basket and in a second mode as a receiver for generating an electronic signal responsive to receipt of a sonic echo pulse from the surface of the load of clothes disposed within the wash basket. The height of the load of clothes disposed within the wash basket may then be determined in accordance with the elapsed time between transmission sonic pulse and reception of the corresponding sonic echo pulse. The wash basket is controlled to rotate while a plurality of sonic pulses are generated and the corresponding sonic echo pulses are received such that a plurality of clothes load heights values are measured and stored. From the plurality of clothes load height values which are measured, an average clothes load height and an average clothes height deviation value may be determined. A modified clothes height value may then be determined in response to the calculated average clothes load heights and the average clothes height deviation value. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a partially cut away elevational view of an automatic washer embodying the principles of the present invention. FIG. 2 is a detailed view showing the cycle control panel of the automatic washer of FIG. 1. FIG. 3 is a schematic illustration of the automatic washing liquid level control system of the present invention. FIG. 4 is a schematic circuit diagram for the automatic washing liquid level control system of the present invention. FIG. 5 is a flow chart showing the operation of the automatic washing liquid level control system of the present invention. FIG. 6 is a flow chart showing the logic utilized in modifying the average clothes height value in response to the average deviation value. FIG. 7 is a simple schematic diagram of the fuzzy controller of the automatic washer of FIG. 1. FIGS. 8a and 8b illustrate input membership functions for the clothes height value and the agitator speed value. FIG. 9 illustrates the fuzzy logic rule base. FIG. 10 illustrates the output membership function for translated the output set to a water level value. DESCRIPTION OF THE PREFERRED EMBODIMENTS In FIG. 1, an automatic washing machine is shown generally at 10 comprising a cabinet or housing 12, and an imperforate tub 14, a concentrically mounted basket 16 with a vertical agitator 18, a water supply 19, an electrically driven motor 20 operable connected via a transmission to the agitator 18 and a pump 24 driven by the motor. An openable lid 26 is provided on the cabinet top of access into the basket 16. A console 28 is provided including a cycle control panel 29 for allowing user input for selectively operating the washing machine through a programmed sequence of washing, rinsing, and spinning steps are provided on a panel 30. An electroacoustic transducer 32 is further provided, disposed on the openable lid 26 of the cabinet. The transducer 32 may also be disposed in a top assembly 33, disposed above the basket 16. The transducer 32 may be used for automatically determining the clothes height as described herein below. FIG. 2 shows a detailed view of the cycle control panel. A plurality of cycle selection buttons are provided for allowing the user to selectively determine the wash cycle. For example, a selection of the "COTTON STURDY" cycle provides a long wash cycle of high speed agitation. A selection of "FINE WASH", however, will provide a short wash cycle of low speed agitation. FIG. 3 is a schematic diagram showing the system of the present invention for automatically filling the wash tub 14 with washing liquid to the optimum level. A microprocessor 40, such as COP820 manufactured by National Semiconductor, is provided for sending a trigger pulse on line 42 to switching circuitry 44. Within the switching circuitry 44, the trigger pulse is inverted and a voltage pulse is produced. The voltage pulse is directed to a driver 46 which typically includes a transformer for producing a high output voltage pulse or electrical excitation pulse. The electrical excitation pulse is directed to the electroacoustic transducer 32 to produce a burst of sonic energy or sonic pulse E. The burst of sonic energy E is directed downwardly into the wash basket 16 containing a load of clothes 48 having a surface 50. The burst of sonic energy E travels down to the surface at the load of clothes 48 and reflects off of the surface 50 causing sonic echo pulse E' to return to the transducer 32. The transducer 32 serves alternately as a receiver for receiving the sonic echo pulsed E' and generating a resultant signal pulse responsive to the sonic echo pulse E'. The resultant signal pulse is directed to a band pass signal amplifier 52. The signal from the band pass signal amplifier 52 is directed to comparator circuitry 54 which allows only signals whose amplitude exceeds a fixed discriminatory threshold value to pass. The comparator circuitry 54 sends a signal to blanking circuitry 56. The blanking circuitry 56 receives an output pulse blanking signal on line 58 from the microprocessor 40 such that an erroneous triggering of the comparator circuitry by the electrical excitation pulse on line 42 or any noise which results immediately thereafter is not taken for the electronic signal pulse responsive to the sonic echo pulse E'. In this fashion, the transducer may function as transmitter and a receiver. The output of the blanking circuitry 56 on line 60 is a signal corresponding in duration to the distance from the surface 50 of the clothes 48 to the transducer 32. From the signal, on line 60, the microprocessor 40 may determine the distance from the surface of the clothes load 50 to the transducer 32 representing the clothes height. A signal corresponding to the sensed clothes height may then be sent on line 61 to a second microprocessor 62. It can be understood that the microprocessors 40 and 62 could be combined, however, in the preferred embodiment the microprocessors are separated to reduce manufacturing requirements. The second microprocessor 62 is further provided with a signal input on line 63 from the cycle control panel 29. The cycle control panel 29 allows for user input for selectively operating the washer 10 through a programmed sequence of washing, rinsing, and spinning steps as discussed above. Dependent on the user selected cycle, the washer 10 is operated through a plurality of steps wherein the motor 20 operates to drive the agitator 18 at either a high, medium or low agitation rate, as is known. The microprocessor 62, therefore, receives signals representative of the clothes height and the desired agitator speed on lines 61 and 63, respectively. Based on these signals, the microprocessor operates to provide output signals for controlling the functions of mixing valves 64 66, as described further herein below. Upon determining the required washing liquid level, the microprocessor 62 initiates the filling operation. During the filling operation, water enters the wash basket 16 through nozzle 68 and the water level is monitored by a pressure sensor 70. The pressure sensor 70 includes a first conduit 72 interconnected with a chamber 74 and a second conduit 76 interconnected with an analog fluid pressure transducer 78 which provides an output signal on line 80 whose frequency is a function of pressure. Such a fluid pressure transducer is disclosed in U.S. Pat. No. 4,671,116, to Glennon et al., the specification of which is incorporated herein by reference. From this signal on line 80, the microprocessor 62 may monitor the washing liquid level. The microprocessor 62 therefore is configured to terminate the flow of water through the mixing valves 64 66 when the water level sensed by the pressure transducer 78 corresponds with the required washing liquid fill level. As described above, the microprocessor 40 causes the transducer 32 to emit a sonic burst E directed toward the load of clothes 48 disposed in the wash basket 16. A critical feature of the present invention is that the microprocessor 62 simultaneously directs an output signal for controlling the operation of the motor 20 such that the wash basket 16 is rotated while a plurality of sonic bursts are directed into the wash basket 16. In this fashion, a plurality of clothes load height measurements are made which correspond to the height of that portion of the load of clothes 48 that passes under the transducer 32 when the basket 16 rotates. Preferably, the measurement should take place at equal intervals around the wash basket. In a manner known per se, the electroacoustic transducer 32, which operates alternately as a transmission transducer and as a reception transducer, can also be replaced by two separate transducers, one of which serves solely as the transmission transducer and the other solely as the reception transducer. Details of the preferred embodiment of the apparatus of the present invention are shown in FIG. 4. The trigger pulse output of the microprocessor 40 is applied through a resistor 100 to the transistor 102. The transistor 102 amplifies and inverts the trigger pulse. The output of the transistor 102 is applied to the gate of MOSFET element 104. The MOSFET element 104 responds to the input from the transistor 102 and applies a signal to the primary of a transformer 106. A high output voltage of the secondary of the transformer 106 is applied along line 108 to the transducer 32. Zenor diodes 110 are provided to limit the output voltage applied to the transducer 32. The output voltage on line 108 drives the transducer causing it to radiate a highly directional, correspondingly frequency-modulated burst of ultrasonic energy as indicated by arrow E. The sonic echo pulse E' produces the resultant signal pulse in the transducer applied along line 109 to a band pass signal amplifier 114. Decoupling diodes 112 function to decouple the transformer secondary from the band pass signal amplifier 52, the comparator circuitry 54 and the blanking circuitry 56. During the transmission of the high output voltage on line 108 and the transmission of the burst of sonic energy E from the transducer 32, the decoupling diodes are effectively a closed circuit to ground. However, during reception of the echo E' and the generation of the resultant signal pulse, the voltage drop across the diodes create an effect of an open circuit to the resultant signal pulse. The output of the band pass signal amplifier is applied through a resistor 116 and a diode 118 clamps the signal 119 to ground. A comparator 120 is provided for comparing the signal on line 119 with a predetermined DC voltage. The blanking circuitry 56 is provided for blanking erroneous triggering of the comparator circuitry and receives the blanking signal on line 58 from the microprocessor 40 and comprises a plurality of amplifiers 122, 124 and a comparator 126. The output of the blanking circuitry is applied on line 60 to the microprocessor 40. The pressure transducer 78 is further shown supplying a signal on line 80 to the microprocessor 40. As described in further detail below, the microprocessor 40 receives the input on lines 60 and 80 and sends a signal on line 130 indicative of the optimum washing liquid level. FIG. 5 illustrates the operation of the apparatus of the present invention during an automatic cycle of operation. FIG. 5 is in a functional block diagram form, with the various blocks indicating steps performed in sequence during the performance of the present invention. The first step 200, as mentioned above, is the initiation of the rotation of the wash basket. Preferably the wash basket is rotated approximately 2-3 rotations while a plurality of distance measurements are made from the surface 50 of the clothes 48 to the transducer 32 as shown in step 202. These distance measurements are made in the aforementioned manner. Steps 204, 206 and 208 illustrate the manner in which an average clothes height valve is determined. Every four distance measurements are averaged and stored in a memory register as described in step 204. The average of the four distance measurements are termed intermediate average height values. The next step 206, involves accumulating sixteen intermediate average height values requiring a total of sixty-four distance measurements and calculating an average clothes height value H. The average height value H for the load of clothes is determined from the average of the sixteen intermediate average height values. In step 208, the average height value H is stored in memory. Steps 212, 214 and 216 illustrate the manner in which an average clothes height deviation value D is determined. In step 212, sixteen intermediate average height deviation valves are calculated by taking the absolute values of the difference between each of the sixteen intermediate average height values and the average height value. In step 214, these sixteen intermediate average height deviation values are averaged to determine the average clothes height deviation value D for the load of clothes. In step 216 the average clothes height deviation value D is then stored in memory. Step 220 covers the use of the average clothes height value H and the average deviation value D in determining a modified clothes height value MH for use in selecting the optimum washing liquid fill level. The logic behind this step is described below. The average clothes height valve H corresponds to the average height of the load of clothes in the wash basket. However, rather than determining the optimum liquid level of washing liquid from only the average height value H, the liquid level is modified by the size of the average clothes height deviation value D. If the average clothes height deviation value D is small, the fill level may be determined based on the average height value H alone. However, if the average clothes height deviation value D is greater than some predetermining minimum, the fill level is modified to be greater than the level which would be determined based on only the average height value H. In this fashion, adequate fill levels of washing liquid are still determined in the presence of large variations in the height of the load of clothes within the wash basket. This may prevent potential clothes damages as well as poor washing results. This logic can be equated to the mental steps required by a user when manually selecting the fill level where the wash load is unevenly distributed in the wash basket such as may occur when washing pillows, blankets or the like. FIG. 6 details the logic utilized in modifying the average clothes height H based on the average deviation value D to arrive at the modified clothes height valve MH. In step 222 it is shown that if the average deviation value D is less than or equal to a first predetermined quantity L1, then the modified clothes height value MH equals the average height value H. In step 224 if the average deviation value D is greater than the first predetermined quantity L1, but less than or equal a second predetermined quantity L2, greater than the first predetermined quantity L1, then the modified clothes height value MH equals the average clothes height value H plus a first predetermined additional height valve X1. It can be seen that this logic continues in step 226 and 228. Finally, if the average deviation value D is greater than a fourth predetermined quantity L4, then the modified clothes height value MH equals the average clothes height value H plus a fourth predetermined additional height valve X4. The modified height value MH is supplied, as shown in step 231, to a fuzzy logic control as will be described in further detail hereinbelow. As shown in FIG. 7, the modified height value MH is communicated to the microprocessor 62 along line 61 and signal representative of the agitation speed is sent to the microprocessor 62 along line 63, as previously described. The microprocessor 62 includes fuzzy control logic, herein called fuzzy control unit 62a, for determining the optimum water level, the output of the fuzzy control 62a being a value which represents the frequency of the analog water level pressure transducer for the output water level. The fuzzy control 62a executes three fuzzy logic stages: fuzzification, rule application and defuzzification, according to the fuzzy theory. The fuzzy logic control may be defined and encoded in Motorola 68HC05 assembly code. In the fuzzification stage, the systems inputs are manipulated and mapped to linguistic values or fuzzy inputs through a set of predetermined membership functions. FIGS. 8a and 8b show membership functions for the input variables, modified height MH and agitation rate AR, for the fuzzy inference of the fuzzy control 62a. In the modified height MH input membership function, FIG. 8a, the ordinate represents the degree of membership and the abscissa represents the modified height value received on line 61. The modified height value ranges from an internal scale from 0 to 255. The triangularly shaped membership functions map the range of clothes height values to degree of membership in the fuzzy sets based on an experts knowledge. For example, it can be seen that a modified height value having an internal scale value of 50 includes a 0.5 membership in the MHIGH clothes height set and a 0.5 membership in the HIGH clothes height set. In this fashion, partial membership in more than one set may be accommodated, according to the fuzzy theory. In the agitator rate AR input membership function, FIG. 8b, the ordinate represents the degree of membership and the abscissa represents the agitator speed for the selected cycle. In the preferred embodiment, as contemplated by the inventor, the automatic washer 10 includes controls for operating the motor to drive the agitator 18 at a selected high, medium or low speed of agitation. The agitation rate AR input is a single value set to 0 for low and medium speed agitation and set to 255 for high speed agitation. In this fashion, it can be seen that a low or medium speed agitation rate leads to an input value fully belonging to the LOW-MED membership function while a high speed agitation rate fully belongs to the HIGH membership function. As described above, the agitator speed will have full membership in either the LOW-MED membership function or the HIGH membership function. However, as contemplated by the inventor, the present invention may readily lend itself to use with a variable speed motor wherein a set of input membership functions may be developed such that partial membership in different membership functions may be provided. In the rule application stage, the logic rules are applied to the set of linguistic input set values or input membership values to derive a set of linguistic output values or conclusions. FIG. 9 illustrates the fuzzy logic rule base applied to the input membership values for determining conclusions or output values for developing an output set. By use of the fuzzy logic rules, a fuzzy inference may be made regarding the linguistic input values from the input membership functions. The rules represent an experts knowledge of water level control based on the size of the wash load and the type of wash cycle selected. Specifically, the rules define conclusions which represent washing liquid levels in the wash tub, based on the input membership function values. For example, in a case #1, where the agitation rate AR linguistic value is HIGH and the modified height MH linguistic value is MHIGH, the conclusion or output water level value is defined as TWELVEIN. The degree membership of the output values or conclusions equals the minimum degree of membership of the input values. For example, in a case #2, where the agitation rate AR linguistic value is HIGH and the modified height MH linguistic value is 0.5 MHIGH and 0.5 HIGH, the output water level values are defined as 0.5 THIRTEENIN and 0.5 TWELVEIN. In the defuzzification stage, the set of rule outputs or output linguistic water level values are applied to an output membership function, illustrated in FIG. 10 for determining the fuzzy controller output for controlling the water level in the wash tub. In this fashion, the set of rule outputs are converted to a single byte output water level through the application of the output membership functions. For the output membership functions, the membership functions are defined as singletons. From the case #1, therefore, when the linguistic output consequent water level value is TWELVEIN, the output membership function converts that linguistic value into a single byte value 162 representative of the desired frequency of the analog fluid pressure transducer 78 wherein the water level may be controlled. From case #2, where the output water level values were 0.5 THIRTEENIN and 0.5 TWELVEIN, a weighted summation of the output membership function provides for an output value of 164 representative of the desired frequency of the analog fluid pressure transducer 78 for controlling the water level. In this fashion therefore, a novel automatic system for determining the optimum quantity of washing liquid in an automatic washer is provided. More specifically, a fuzzy control system utilizing the inputs of clothes height and agitator speed is provided for determining the optimum water level. Although the present invention has been described with reference to a specific embodiment, those of skill in the Art will recognize that changes may be made thereto without departing from the scope and spirit of the invention as set forth in the appended claims.
An automatic washing machine having an automatic washing liquid level control system including an ultrasonic apparatus for detecting the height of the clothes load in the washing machine and generating a signal representative of the clothes height, a control panel means for allowing user selection of the agitator speed, and means for generating a signal representative of the desired agitator speed. A control unit is provided including a fuzzy control which performs fuzzy inference on the basis of the signal representative of the clothes height and the signal representative of the agitator speed such that the optimum washing liquid level is achieved. In particular, membership functions according to fuzzy theory are defined for the clothes height and the agitator speed. Rules are defined for the height and agitator speed conditions such as for very high clothes height and low agitator speed, or medium high clothes height and high agitator speed, and so on. Each rule is executed using the fuzzy theory to thereby achieve an optimum washing liquid level.
3
CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation of the U.S. National Stage designation of co-pending International Patent Application PCT/IB02/04061 filed Oct. 2, 2002, the entire content of which is expressly incorporated herein by reference thereto. FIELD OF THE INVENTION The present invention relates to a burner, for operation in a combustion chamber, preferably in combustion chambers of gas turbines, which substantially comprises a swirl generator for a combustion air stream and means for introducing fuel into the combustion air stream, the swirl generator having combustion-air inlet openings for the combustion air stream which enters the burner, and the means for introducing fuel into the combustion air stream comprising one or more first fuel feeds having a group of first fuel outlet openings, arranged distributed around the burner axis at a combustion chamber-side end of the burner. A preferred application area for a burner of this type is in gas and steam turbine engineering. BACKGROUND OF THE INVENTION EP 0 321 809 B1 has disclosed a conical burner comprising a plurality of shells, known as a double-cone burner. The conical swirl generator, which is composed of a plurality of shells, generates a continuous swirling flow in a swirl space, which on account of the swirl increasing in the direction of the combustion chamber becomes unstable and changes into an annular swirling flow with backflow in the core. The shells of the swirl generator are assembled in such a manner that tangential air inlet slots for combustion air are formed along the burner axis. Feeds for the premix gas, i.e. the gaseous fuel, which have outlet openings for the premix gas distributed along the direction of the burner axis, are provided at these air inlet slots at the leading edge of the cone shells. The gas is injected through the outlet openings or bores transversely with respect to the air inlet gap. This injection, in conjunction with the swirl of the combustion air/fuel gas flow generated in the swirl space, leads to thorough mixing of the combustion or premix gas with the combustion air. Thorough mixing is a precondition in these premix burners for lower NO x emissions during combustion. To further improve a burner of this type, EP 0 780 629 A2 has disclosed a burner for a heat generator which, following the swirl generator, has an additional mixing section for further mixing of fuel and combustion air. This mixing section may, for example, be designed as a section of tube which is connected downstream and into which the flow emerging from the swirl generator is transferred without significant flow losses. The additional mixing section makes it possible to further increase the degree of mixing and therefore to further lower the pollutant emissions. WO 93/17279 has described a further known premix burner, in which a cylindrical swirl generator with a conical inner body is used. In the case of this burner, the premix gas is likewise injected into the swirl space via feeds with corresponding outlet openings which are arranged along the axially running air inlet slots. In the conical inner body, the burner additionally has a central feed for fuel gas, which can be injected into the swirl space close to the burner outlet for pilot control. The additional pilot stage is used to start up the burner and to widen the operating range. EP 1 070 915 A1 has disclosed a premix burner in which the fuel gas supply is mechanically decoupled from the swirl generator. As a result, when fuel gases that have not been preheated or have been only slightly preheated are used, stresses caused by thermal expansions are avoided. In this case, the swirl generator is provided with a row of openings, through which fuel lines for gas premix operation, which are mechanically decoupled from the swirl generator, project into the interior of the swirl generator, where they supply gaseous fuel to the swirled-up flow of combustion air. These known premix burners of the prior art are what are known as swirl-stabilized premix burners, in which a fuel mass flow, prior to combustion, is distributed as homogeneously as possible in a combustion air mass flow. In these types of burners, the combustion air flows in via tangential air inlet slots in the swirl generators. The fuel, in particular natural gas, is typically injected along the air inlet slots. In gas turbines, in addition to natural gas and liquid fuel, generally diesel oil or Oil#2, in recent times synthetically produced gases, known as Mbtu and Lbtu gases, also have been used for combustion. These synthesis gases are produced by the gasification of coal or oil residues. They are characterized by mostly comprising H 2 and CO. In addition, there is a smaller proportion of inert constituents, such as N 2 or CO 2 . In the case of the combustion of synthesis gas, the injection which has proven successful for natural gas in burners of the prior art cannot be retained, on account of a high risk of flashback. This results in the following peculiarities and requirements in a burner that is to be operated with synthesis gas as distinct from a burner using natural gas. Depending on the dilution of the synthesis gas, which is known per se from the prior art, synthesis gas requires a fuel volumetric flow which is around four times—and in the case of undiluted synthesis gas up to seven times or even more—higher than comparable natural gas burners, so that with the same gas holes in the burner, significantly different pulse ratios result. On account of the high hydrogen content in the synthesis gas, and the associated low ignition temperature and high flame velocity of the hydrogen, the fuel is highly reactive, so that in particular the flashback characteristics and the residence time of ignitable fuel-air mix in the vicinity of the burner need to be investigated. Furthermore, stable and safe combustion of synthesis gases for a sufficiently wide range of calorific values has to be ensured, despite the synthesis gas having different compositions depending on the process quality of the gasification and starting product, for example oil residues. In order, under these conditions, nevertheless to achieve premixing and therefore the typical lower emissions during combustion, these synthesis gases are generally diluted with the inert constituents N 2 or steam prior to combustion. Moreover, this improves the stability of combustion and in particular reduces the risk of flashback which is inherent to the high H 2 content. Therefore, the burner has to be able to safely and stably burn synthesis gases of different compositions, in particular of different dilutions. Furthermore, it is advantageous if, in addition to the synthesis gas, the burner can also safely burn a reserve fuel, known as a back-up fuel. In the case of the highly complex integrated gasification combined cycle (IGCC) installation, this requirement results from the demand for high availability. In such a situation, the burner should function safely and reliably even in mixed operation using synthesis gas and back-up fuel, for example diesel oil, while maximizing the fuel mix spectrum that can be used for burner operation in mixed operation of an individual burner. Of course, low levels of emissions (NO x ≦25 vppm, CO≦5 vppm) should be ensured for the fuels which are specified and used. EP 0 610 722 A1 has disclosed a double-cone burner, in which a group of fuel outlet openings for a synthesis gas are arranged at the swirl generator, distributed around the burner axis, at a combustion chamber-side end of the burner. These outlet openings are supplied via a separate fuel line and allow the burner to operate with undiluted synthesis gas. Working on the basis of this prior art, the present invention relates to a burner which ensures safe and stable combustion both for undiluted synthesis gas and for dilute synthesis gas and moreover has a long service life. The burner should in particular satisfy the requirements listed above and, in preferred refinements, should allow operation with a plurality of types of fuel, including in mixed operation. SUMMARY OF THE INVENTION The present burner comprises, in a known way, a swirl generator for a combustion air stream and means for introducing fuel into the combustion air stream. The swirl generator has combustion-air inlet openings for the combustion air stream, which preferably enters the burner tangentially. The means for introducing fuel into the combustion air stream comprise one or more first fuel feeds having a group of first fuel outlet openings, arranged distributed around the burner axis at a combustion chamber-side end of the burner, i.e. at the burner outlet. The present burner is distinguished by the fact that the one or more first fuel feeds having the group of first fuel outlet openings are mechanically decoupled from the swirl generator. The geometry of the swirl generator, and also of an optional swirl space, can be selected in various ways in the present burner, and in particular may have the geometries which are known from the prior art. The fact that the first fuel outlet openings are distributed exclusively at the combustion chamber-side end of the burner or swirl space, around the burner axis, reliably prevents flashback of the synthesis gas. Mixing with the combustion air emerging from the burner is nevertheless ensured. Synthesis gas with a high hydrogen content (45% by volume) can be burnt in undiluted form (LHV=14,000 kJ/kg). The burner therefore allows safe and stable combustion both of undiluted synthesis gas and of dilute synthesis gas. This ensures a high degree of flexibility when using a gas turbine equipped with burners according to the invention in an IGCC process. By using a configuration of the first fuel feed with a correspondingly adapted cross-section, it is possible to safely pass high volumetric flows, up to a factor of 7 compared to the supply of natural gas in known burners from the prior art, to the location of injection at the burner outlet. In the case of the present burner, the one or more first fuel feeds with the associated first fuel outlet openings are mechanically and thermally decoupled from the swirl generator or the burner shells which form the swirl generator and are significantly warmer in operation. As a result, the thermal stresses between the relatively cold first fuel feeds, also referred to below as gas passages, and the warmer burner shells are avoided or at least greatly reduced. For example, in one embodiment of the present invention, as is explained in more detail in the exemplary embodiments, the injection area for the synthesis gas in the burner shells is completely cut out. The first gas passage is directly anchored in this cutout of the burner shells. As a result, gas passage and burner shells are thermally and mechanically decoupled from one another, and the design problem at the connecting locations between cold gas passage and warm burner shell is resolved. Earlier designs, such as those shown in EP 0 610 722 A1, had problems particularly with regard to the connection of relatively cold gas passage to hot burner shell, for example had cracked resulting from the high concentration of stresses at these connecting locations. The required service life of the burner is achieved by the decoupled solution and the proposed design. The decoupling of individual fuel lances from the burner shells is already known from EP 1 070 915. In the present burner, however, this mechanical decoupling is for the first time realized using integral gas passages with circumferentially homogeneous introduction of gas. Compared to the injection of gas which is known from EP 1 070 950, the circumferentially homogeneous injection of gas in accordance with the invention has benefits in terms of achieving a significantly more uniform distribution of the fuel in the combustion air, and therefore, in particular when using Lbtu and Mbtu fuels, improved emission levels combined, at the same time, with a good flame stability. There is no need for complex specific heat insulation for the gas passage with respect to the hot burner shell, for example by means of the known gas passage inserts. It is preferable for the burner, in addition to the first fuel feed(s), also to have one or more second fuel feeds having a group of second fuel outlet openings at the swirl body, arranged substantially along the direction of the burner axis. As an alternative or in combination with this measure, it is also possible to provide a fuel lance, arranged on the burner axis, for the injection of liquid fuel, this fuel lance projecting into the swirl space in the axial direction. The arrangement and configuration of these additional fuel feeds may, for example, be based on known premix burner technology as described in EP 321 809 or on other designs, for example as disclosed by EP 780 629 or WO 93/17279. Burner geometries of this type can be designed with the features according to the invention for the combustion of synthesis gases, in particular for the combustion of Mbtu and Lbtu fuels. The preferred design of the present burner with one or more further fuel feeds results in a multifunctional burner which safely and stably burns a very wide range of fuels. The burner in particular ensures the stable and safe combustion of Mbtu synthesis gases with calorific values (net calorific value NCV or lower heating value LHV) of 3500–18,000 kJ/kg, in particular 6000 to 15,000 kJ/kg, preferably of 6500 to 14,500 kJ/kg or from 7000 to 14,000 kg/kJ. In addition to the safe and stable combustion of undiluted and dilute synthesis gas, it is also possible to use liquid fuel, for example diesel oil, as back-up fuel. In this case, the calorific value of the fuels used may differ significantly, for example in the case of diesel oil a calorific value LHV=42,000 kJ/kg, and in the case of synthesis gas a calorific value of 3500–18,000 kJ/kg, in particular 6000 to 15,000 kJ/kg, preferably from 6500 to 14,500 kJ/kg or from 7000 to 14,000 kg/kJ. It is also possible for the additional fuel used to be natural gas. In this case, the injection of natural gas may take place either in the burner head through the burner lance and/or via the second fuel feeds, which are usually formed by the gas passages arranged along the air inlet slots at the swirl generator or swirl body, with which the person skilled in the art will be familiar, for example from EP 321 809. In this way, the burner can be operated with three different fuels. The injection of the synthesis gas, i.e. of the Lbtu/Mbtu fuel, takes place via the first outlet openings, radially at the burner outlet. These outlet openings are small outlet passages, the passage axis of which defines the axial injection angle α. Diameter D and injection angle α of these outlet openings or passages are specific parameters which can be selected appropriately by the person skilled in the art depending on the boundary conditions, for example the specific gas composition, the emissions, etc. The injection angle may in this case be selected in such a way that the passage axes of all the outlet openings intersect at one point on the burner axis, downstream of the burner or swirl space. To achieve optimum matching of the synthesis gas used to the desired emission levels, it is also possible for the injection angles to be selected in such a way that the passage axes of subgroups of the outlet openings intersect at different points. In this way, it is possible to achieve any desired distribution of the injected fuel at the burner outlet. It is also possible to vary an injection angle with respect to the burner radius. The fuel feeds for combustion of the synthesis gas are designed for a volumetric flow of fuel which is up to 7 times greater, and in particular provide the required cross-sections of flow. In this case, the cross-section is larger by a multiple than that of the feeds for natural gas. In the case of oil being used as fuel, the design which is known from the prior art, with the oil or oil-water emulsion being injected via the burner lance, is retained. Gas turbines which burn synthesis gas have to ensure mixed operation of ignition fuel and synthesis gas by using different boundary conditions, such as incorporation of the gas turbine in the IGCC process or fixed burner groupings that are to be retained. The burner described here functions stably and safely even in mixed operation using diesel oil and synthesis gas in various mixing ratios. It can be safely operated in mixed operation for prolonged periods of time. Therefore, the gas turbine achieves further flexibility and in operation can change from one fuel to the other. The possibility of mixed operation represents a significant operating advantage. BRIEF DESCRIPTION OF THE DRAWINGS The present invention is explained briefly below, without restricting the general concept of the invention, with reference to exemplary embodiments in conjunction with the figures, in which: FIG. 1 shows a highly diagrammatic illustration of a premix burner as is known from the prior art; FIG. 2 shows a sectional view of the combustion chamber-side region of a burner in accordance with an exemplary embodiment of the present invention; FIG. 3 shows a three-dimensional sectional view of a burner designed in accordance with the exemplary embodiment shown in FIG. 2 ; FIG. 4 shows an example of the mounting of a burner as shown in FIGS. 2 and 3 ; FIG. 5 shows a highly diagrammatic plan view of a plurality of different injection geometries for synthesis gas in the burner according to the invention; FIG. 6 shows an example of a possible configuration of the burner with a conical inner body; and FIG. 7 shows an example of a further possible configuration of the burner. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows a highly diagrammatic illustration of a premix burner as is known, for example, from EP 321 809 A1. The burner is composed of a burner head 10 and an adjoining swirl generator 1 , which forms a swirl space 11 . In a burner of this type, the conical swirl generator 1 comprises a plurality of burner shells, between which tangential inlet slots for combustion air 9 are formed. In the figure, the combustion air 9 which enters is indicated by the long arrows. Furthermore, gas feeds 24 for the supply of a fuel, in particular natural gas 26 , via the tangential air inlet slots leading into the swirl space 11 can be provided along the tangential inlet slots. This is indicated by the short arrows in the figure. A burner lance 14 extends from the burner head 10 into the swirl space 11 ; a nozzle 16 for the injection of liquid fuel 13 , e.g. oil and/or water 12 , is provided at the end of this burner lance 14 . The burner lance 14 is used in particular for ignition of the burner. The combustion air 9 which enters via the tangential air inlet slots at the swirl generator 1 is mixed with the injected fuel in the swirl space 11 . The continuous swirling flow which is generated in the process becomes unstable on account of the increasing swirl at the end of the swirl space 11 on account of the sudden widening in cross section at the transition to the combustion chamber, and is converted into an annular swirling flow with back flow in the core. This area forms the start of the reaction zone 17 in the combustion chamber. A burner of this type cannot be operated with synthesis gas, however, on account of the high risk of flashback with this fuel. In a first exemplary embodiment, FIG. 2 shows a sectional view through the combustion chamber-side region of a burner according to the invention for operation with synthesis gas. The Lbtu/Mbtu fuel is injected through gas holes 18 , which are to be selected appropriately in terms of diameter D and injection angle α, in the radial direction at the burner outlet, i.e. at the end of the swirl space 11 . This radial injection at the burner outlet also makes combustion of the hydrogen-rich synthesis gas in undiluted form possible. Diameter D and injection angle α of the radial gas injection are specific parameters which are selected appropriately by the person skilled in the art depending on boundary conditions (specific gas composition, emissions, etc.). In this context, the figure shows the burner shells of the swirl body 1 which surround the swirl space 11 . Outside this swirl body there is arranged a gas feed element 2 which radially surrounds the swirl body 1 and forms the first fuel feed passage(s) 19 for the supply of the synthesis gas. First outlet openings 18 for the synthesis gas are formed at the combustion chamber-side end of this gas feed element 2 . These outlet openings 18 form outlet passages which predetermine the direction of injection of the synthesis gas. The injection angle α and the diameter D of these passages or openings 18 are selected appropriately by the person skilled in the art depending on the particular requirements. In the present example, the outlet openings 18 are arranged in a row around the burner axis 25 , so that circumferentially homogeneous injection of the synthesis gas is achieved. The relatively cold fuel feed passages 19 for injection of the synthesis gas, and the in theory significantly warmer burner shells of the swirl generator 1 are thermally and mechanically decoupled from one another. As a result, the thermal stresses are significantly reduced. The connection between the gas feed element 2 and the swirl generator 1 is in this example effected by means of lugs 3 and 4 which are provided on both components and are connected to one another. This minimizes thermal stresses. An air flow 8 which is also illustrated in the figure tends to stabilize the flame and generates a swirl cooling effect at the burner front upstream of the outlet. The figure also shows the opening or circumferential gap 7 of the swirl generator 1 , which is required in order to allow a connection between the outlet openings 18 of the gas feed element 2 and the swirl space 11 . FIG. 3 once again shows a burner designed in accordance with FIG. 2 , in a three-dimensional sectional view. In this illustration too, the swirl generator 1 formed from a plurality of burner shells, and the gas feed element 2 surrounding it, can be seen. This gas feed element 2 may form an annular feed slot as fuel feed passage 19 or may also be divided into separate fuel feed passages 19 . Of course, it is also possible for individual pipelines to be routed to the outlet openings 18 as fuel feed passages 19 . The design of the fuel feed passages 19 for the synthesis gas is adapted for a volumetric flow of fuel which is up to 7 times greater for the combustion of synthesis gas, and in particular provide the required large cross sections of flow, as can be seen from FIG. 3 . In the present example, the injection region for the fuel, i.e. the synthesis gas, is completely cut out in the burner shells. In this case, the gas feed element 2 is anchored directly in this cutout of the burner shells of the swirl generator 1 . In this way, the problem of stresses at the connecting locations between cold gas feed element 2 and warm burner shell is solved. The decoupled solution illustrated in this example results in the required service life of the burner. The injection of the synthesis gas is indicated by reference numeral 20 in the figure. Of course, with a burner of this type, it is also possible for additional gas injection passages 24 to be provided along the swirl generator 1 , in a similar way as can be seen, for example, from FIG. 1 , by means of which passages, by way of example, natural gas 26 can be introduced into the swirl space 11 upstream of the location where the synthesis gas is injected. The injection of oil or an oil-water emulsion is diagrammatically indicated at the combustion head-side end of the swirl space 11 , as is the incoming flow of combustion air 9 via the tangential inlet slots. FIG. 4 shows, by way of example, the assembly of a burner as shown in FIGS. 2 and 3 from the two components, namely the gas feed element 2 and the swirl generator 1 . The gas feed element 2 with the integrated one or more fuel feed passages 19 for synthesis gas and the outlet openings 18 arranged distributed around the burner axis 25 on the combustion chamber side is preferably produced as a casting together with the swirl generator 1 , and the two components are then separated. Assembly is carried out by the swirl generator 1 being introduced axially into the gas feed element 2 , so that the outlet openings 18 of the gas feed element 2 come to lie in corresponding openings 7 in the swirl generator 1 . In the burner head region, an element 6 of the swirl generator 1 is held in a sliding fit in a mating piece 5 of the gas feed element 2 , so that differential thermal expansions between swirl generator 1 and gas feed element 2 in the region of the burner head can be freely compensated for. In the region of the burner front, the connecting lugs 3 of the gas feed element 2 and the connecting lugs 4 of the swirl generator 1 are joined to one another in a suitable way, for example by welding, and form the only fixed bearing of the swirl generator 1 in the gas feed element 2 . The outlet opening region of the gas feed element 2 can move freely in the openings 7 in the swirl generator 1 . Producing the two elements from a casting allows minor manufacturing tolerances, so that it is possible to minimize an encircling gap dimension s, illustrated in FIG. 2 , between swirl generator 1 and gas feed element 2 . A correspondingly high mating accuracy with a small gap dimension s in the region of the gas outlet openings 18 and/or the openings 7 in the swirl generator 1 minimizes any unswirled combustion air emerging through this gap, which could potentially have adverse effects on the stability of combustion. FIG. 5 shows various examples for differently selected injection directions of the first outlet openings 18 at the end of the swirl space 11 for the synthesis gas. In this context, FIG. 5 a shows a greatly simplified illustration of a plan view of the burner outlet and the injection axes of the synthesis gas injection 20 from the individual outlet openings 18 , which intersect one another at an intersection point 21 on the burner axis. FIG. 5 b shows a further exemplary embodiment, in the same view, in which the outlet axes of the synthesis gas injection 20 of different groups of outlet openings 18 intersect at different intersection points 21 which are distributed over the outlet cross section of the burner. It will be readily understood that the distribution of these intersection points 21 can be selected as desired in order to adapt the injection to the prevailing conditions. This is true firstly of the position of the intersection points 21 and secondly, of course, of the number of such points. In the same way, it is possible for the intersection points 21 to be selected to lie at different distances from the outlet plane of the burner, or at the same distance from this plane, as is diagrammatically illustrated in FIGS. 5 c and 5 d. FIG. 6 shows an example of a swirl generator 1 with a purely cylindrical swirl body 23 , into which a conical inner body 22 is inserted. In this case, the pilot fuel can be supplied directly to the tip of the conical inner body 22 . In this case too, the outlet openings 18 for the synthesis gas are arranged distributed around the burner axis 25 at the combustion chamber-side end of the swirl space 11 . The fuel feed passages 19 are not shown in this illustration. In this case too, it is additionally possible for further gas outlet openings for natural gas, including the feed lines 24 required for this purpose, to be provided at the tangential air inlet slots (not shown). Furthermore, in this exemplary embodiment, as in the exemplary embodiments described above, a mixer tube for generating an additional mixing section may follow the swirl generator 1 , as is known from the prior art. Finally, FIG. 7 also shows an example of a burner in which the swirl generator 1 is designed as a swirl grating, by means of which incoming combustion air 9 is swirled up. An additional fuel for premix loading can be introduced into the combustion air 9 via the feed lines 24 leading to outlet openings in the region of the swirl generator 1 . The pilot fuel 15 is supplied via a nozzle 16 which projects centrally into the internal volume 11 . In this burner too, the outlet openings 18 for the synthesis gas are arranged distributed around the burner axis 25 at the combustion chamber-side end of the inner volume 11 and are supplied with synthesis gas via the fuel feed passages 19 . Although the invention has been presented primarily on the basis of a double-cone burner of the type which is known from EP 321 809, the person skilled in the art will readily recognize that the invention can also be applied to other types of burner and swirl generator geometries, as known, for example, from EP 780 629 or WO 93/17279. Of course, modifications to these burner geometries are also possible, provided that the purpose of the swirl generator, i.e. that of generating a swirling combustion air flow, is still ensured.
The present invention relates to a burner, substantially comprising a swirl generator for a combustion air stream and means for introducing fuel into the combustion air stream, the swirl generator having combustion-air inlet openings for the combustion air stream that enters the burner, and the means for introducing fuel into the combustion air stream comprising one or more first fuel feeds having a group of first fuel outlet openings, arranged distributed around the burner axis at a combustion chamber-side end of the burner. The burner is distinguished by the fact that the one or more first fuel feeds having the group of first fuel outlet openings are mechanically decoupled from the swirl generator. The present burner allows reliable and safe use of synthesis gas in both dilute and undiluted form as fuel.
5
This is a continuation, of application Ser. No. 359,124 filed May 10, 1973, now abandoned. BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to methods and apparatus for the production of novel and improved carpet yarns, and more particularly, to the production of heavy denier continuous filament yarns for cut-pile carpets, although the processes herein described may also have application to the production of yarns for other purposes, such as spun yarns for handknitting. 2. Prior Art The process described herein has been found to have especially significant application in the field of yarns which are produced from synthetic filament yarns which have been "pre-bulked" by the producer thereof in connection with the yarn spinning and manufacturing processes. Such yarns, produced and sold, for example, by the E. I. DuPont de Nemours Company, are known in the trade as "BCF" yarns, meaning "bulked continuous filament" yarns. These are yarns which have been endowed with certain properties by the yarn producers in the manufacturing processes, by heretofore unspecified means, which result in such filament yarns possessing certain latent tendencies to subsequently crimp or deform under the application of certain conditions of heat and moisture. It has been found, however, that BCF yarns should not be initially subjected to temperature conditions that are overly severe, so that these yarns, which also have thermoplastic properties, do not become "set" prior to or concurrently with the onset of the manifestation or development of the theretofore latent properties in the yarn. Moreover, it is known that the application of linear tensions, such as are common in the continuous processing of yarns, during the period of the supposed development of manifest crimp will significantly retard or even suppress entirely the development of the full crimp properties possessed by the BCF yarns. It has also been found that the crimp characteristics of BCF yarns, once developed and made manifest, are extremely fragile and can still be distorted, damaged, or even destroyed altogether by the subsequent handling processes which are commonly employed in the textile trade. For purposes of an illustrative example, a synthetic or thermoplastic yarn which is texturized in the currently widely employed false-twist process is continuously subjected to linear tensions on the order of at least 0.06 grams/denier, and the yarn, after receiving its manifest crimp by removal of twist, is usually subjected to tensions of about 0.4 grams/denier or higher without, however, materially adversely affecting the final texture or crimp in the finished yarn. Such tensions, applied to BCF yarns, upon the manifestation of their crimp characteristics, simply straighten and permanently remove the crimped deformations, thereby rendering the yarn substantially untexturized, and in any event, entirely unsuitable for the desired end uses. Heretofore, all of the known processes for producing commercially suitable yarns for BCF yarns have been limited by the factors mentioned above, to the step-by-step formation, handling and multiple treatment of discrete hanks or skeins of the yarn. These known processes, and the resulting yarn products, are subject to a plurality of inherent defects, deficiencies and inefficiencies. Among these are the following: (a) loss of significant latent crimp properties, which are never developed and made manifest in the yarn; (b) removal and eventual loss of manifested crimp by the required subsequent handling processes; (c) nonuniform development of manifest crimp; (d) non-uniformity of dye-uptake, resulting in "streakiness" in the finished product; and (e) excessive costs due to the number of handling operations and treatments that must be applied to obtain yarns of minimum suitability for the desired end use. Accordingly, it is an object of the present invention to provide a method for processing BCF yarns so as to initially develop and render manifest, and to a significantly greater extent than previously possible, substantially all of the latent properties induced therein by the yarn producer; for further processing the yarns, without substantially degrading or damaging the latent properties which have been rendered manifest; and for permanently fixing or setting the thus manifest properties so as to produce yarns useful for carpets and the like which retain their full, uniform, bulk and crimp throughout subsequent finishing and manufacturing operations and display significantly improved and durable bulk and "cover" while in service. It is a further object of the invention to provide a method for bulking and setting BCF yarns in a continuous process which substantially reduces the number of lengthy and expensive operations required by previously-known processes. It is a further object to provide carpet yarns for cut-pile carpets and the like which display substantially increased bulk and cover, as compared with like yarns of the same weight which are produced by prior art methods. It is a further object of the present invention to provide carpet yarns for cut-pile carpets and the like which display unique aesthetic qualities and improved covering properties, as compared to like yarns produced by previously-known methods, by reason of an irregular linear formation permanently set in the yarns. It is a still further object to provide means and apparatus for efficiently and economically carrying out the methods herein disclosed, and achieving these and other objects of the present invention. SUMMARY OF THE INVENTION The above objects are achieved by providing a process wherein a yarn having pre-existing latent crimp characteristics is first slightly twisted with a low number of turns per inch in one direction and then plied with a similar strand or strands of yarn having a twist in the same direction, the strands being given a ply twist approximately the same number of turns per inch as were inserted into each individual strand, but in the opposite direction. These plied strands are then wound on a rotating mandrel adapted to spirally convey said yarn along the longitudinal length of the mandrel. As the yarn is carried along the mandrel, it is continuously advanced through a first treatment zone wherein it is subjected to predetermined conditions of temperature and moisture that develop the latent crimp characteristics of the yarn and render them manifest, but without setting the yarn. As the yarn advances through the treatment zone the rotating of the mandrel, in conjunction with the longitudinal movement of the yarn along the mandrel, results in each yarn segment being subjected to at least the same minimum conditions of temperature and moisture. The yarn is then continuously removed from the opposite end of the mandrel utilizing a minimum amount of tension to remove the yarn, which tension is immediately relieved thereafter as the plied yarn is then drawn through a set of feed rolls, and is subsequently deposited under no appreciable tension in treatment container. The yarn is deposited in a manner that provides a substantially uniform un-compacted mass of yarn within the container. Once the container is substantially filled, it is removed and positioned in a second treatment zone wherein more severe conditions of humidity and temperature are applied which are adequate to permanently set the manifest crimp characteristics in the yarn. The yarn is then removed from the second treatment zone and can be subsequently fabricated into carpet pile, or as otherwise desired. Carpets from yarns so produced have been found to have substantially greater cover and bulk than like yarns processed according to previously known methods, for the same weight of yarn. It has also been found that when the filling of the container is accomplished by rotating the cylindrical container as the yarn is being deposited by a reciprocating member which carries the yarn back and forth along the radius of the axis of rotation of the container, significantly different and desirable characteristics are imparted to the finished yarn, which further improve the cover of the yarn after fabrication into carpet. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a diagrammatic view illustrating the sequence of yarn treatment and relative position of the components of the apparatus useful in the practice of the present invention; FIG. 2 is a diagrammatic view further illustrating the depositing of the treatment container, and also illustrating an arrangement wherein a plurality of containers which may be simultaneously filled according to the practice of the invention; FIG. 3 is a partial diagrammatic view showing the construction of feed rolls which may be used to deposit the yarn in the containers. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Our preferred procedures may conveniently be described in connection with, and by reference to, the particular apparatus disclosed in the above-identified drawings. However, it should be understood that the diagrammatical representation of apparatus pictured therein is merely for the purpose of illustration and is not intended as a limitation in respect to the type or form of apparatus that may be employed. Referring generally to FIG. 1, the specially prepared yarn, described in greater detail below, is processed through a yarn winding apparatus A wherein a plied yarn 10, unwound from a package 12, is supplied to one end 16 of a rotating mandrel 18 by means of a rotating flyer 19. Rotating mandrel 19 consists of a series of suitably supported conveyor belts 20, four or six for example, which are spaced around the axis of rotation of mandrel 18, and converge toward that axis as the distance from the flyer 19 increases. The outer surfaces of conveyor belts 20 are adapted to travel away from the flyer, toward the opposite end 22 of mandrel 18. This movement, in conjunction with the mandrel rotation, causes yarn 10 to spirally advance along mandrel 18 as the yarn is continuously laid thereon by the flyer. The plied yarn 10 may be prepared by first lightly twisting a suitable BCF yarn, for example, a 1200 denier nylon yarn containing 68 filaments. The twist given this yarn may be on the order of 2.5 to 4.5 turns per inch, in the z direction. This twisting may be accomplished by any known means, such as the well known "up-twister" apparatus, but special care should be taken to ensure the uniformity of twist in the yarn. After twisting, two or more similar strands, each of which have been twisted to substantially the same level and in the same direction (Z or S), are plied together, receiving in the process a ply twist in the opposite direction from that of the "singles" yarn, and to substantially the same level of twist. Thus, if each of the singles yarns were given a twist of three turns per inch in the Z direction, then the ply twist should then preferably be three turns per inch in the S direction. Again, the plying may be carried out by any of the well known means available to the textile trade and, for that reason, a more detailed description of the apparatus and of the precise methods of obtaining the plied yarn 10 should not be required by those of skill in the art. When the plied yarn 10 is laid upon the mandrel end 16, the movement of the belts 20 will ordinarily ensure that the subsequent winding of yarn will not be superimposed upon prior windings, but will contact the tape along a path longitudinally spaced from the path of the previous winding. It will be recognized from the preceding descriptions that the spacing between adjacent coils of yarn on the mandrel 18 can thus be varied, depending upon the chosen speed of rotation of the flyer 19 and the chosen linear speed of the belts 20. We have found that the precise spacing between adjacent coils of yarn 10 is not critical, but it is important, however, that a plurality of coils of the yarn not be permitted to bunch together or become superimposed upon one another, as those conditions may adversely affect or defeat the results otherwise achieved by the use of our invention. Preferably, some spacing, however slight, should be maintained between adjacent coils so as to permit passage of air currents through the windings to thus ensure thorough heat and moisture penetration of the yarn, as hereinafter more fully described. As yarn 10 advances along mandrel 18, it passes into and through a treatment zone which may conveniently comprise compartments 21, 23 and 25. Heated and moisturized air enters the treatment zone in compartment 23 so as to maintain that compartment under temperature and humidity conditions on the order of 180° - 190° F dry bulb and 170° F wet bulb. Exhaust ducts in compartment 23, either alone or in combination with ducts in compartment 21, draw off air thereby creating circulation of the heated and moisturized air and promoting uniform distribution of heat and humidity throughout compartment 23. Due to the rotation of converging mandrel 18, each linear segment of yarn 10 passing therethrough is thus subjected to essentially the same conditions existing in the treatment zone, which permits uniform treatment of the yarn should there be any variation in the processing conditions from one portion of the zone to another. It is important to note that the treatment zone is disposed along the longitudinal axis of the mandrel 18 a sufficient distance from end 16 so that, due to the decreasing circumference to the mandrel, the coils of yarn lay very slack and loose about the belts 20, and without tension other than that caused by the weight of the yarn in each coil, when first subjected to the heat and moisture conditions mentioned above. We have found that the yarn thus arranged on the mandrel is uniquely capable of developing its latent crimp properties to a greater extent than that previously obtainable under known conditions of heat and moisture. As the plied yarn 10 passes into and through compartment 23, the latent properties of the yarn are thus developed by the passage of the heat and moisturized air in intimate contact with the yarn and each linear segment of the yarn is also subjected to essentially the same conditions of heat and moisture in a tension-free state. We have found also that the uniformity of dye uptake of the finished yarn is considerably improved, thus eliminating streakiness in the fabricated carpet, when, according to the procedures described herein, each segment of the yarn is subjected uniformly to the minimum heat and moisture conditions which are required to develop the latent properties of the yarn. Surprisingly, however, we have also found that, once this development has taken place, further dwell time of the yarn in the treatment zone has no apparent deleterious effects, either with respect to crimp, tenacity or dyeability, in the finished yarn. As the yarn 10, having received full development and manifestation of its latent properties, proceeds through compartment 25 on the mandrel, it is dried somewhat by a counter-current of air adjacent to the mandrel, which is drawn from outside the zone. Upon reaching the small end 22 of the mandrel, the yarn 10 still remains somewhat damp, however, and is still supported very loosely by the belts 20 so as not to damage or remove the very fragile crimp formations which have been developed in the treatment zone. The yarn 10 must thus be removed from the mandrel with extreme care and under the minimum tensions obtainable. We have found that the normal winding operations employed in the textile industry apply much greater tensions than the manifest crimp formations can withstand, and we, therefore, deem the following steps of removing the yarn from the mandrel to be of particular importance. The yarn 10 is drawn over-end from the mandrel by the action of driven rollers 30 and 32. The yarn is then led to the rollers 30, 32 through a centering guide 27 which is in generally axial alignment with the mandrel, and then through a guide 28 which is mounted on a reciprocating shaft 31 so as to longitudinally traverse the feed rolls 32 and 30. Upon passing through the rolls 32, 30 all measurable tension on the yarn is relieved, and the yarn is deposited in the cylindrical treatment container 34. By adjusting the linear speed of the feed roll surfaces to the speed of rotation of the flyer, we can remove the yarn at speeds of 800 yarns per minute without inducing tensions in the yarn greater than about 0.015 grams per denier. Tensions of at least 0.01 grams per denier are difficult to avoid, simply due to the weight of the ballooning yarn as it is removed from the mandrel. However, despite the fragile nature of the crimp in the yarn, we have found that when the rolls 32, 30 are placed within a distance of about 10 feet from the end of the mandrel, the yarn is subjected to the aforementioned tensions for a period of less than about three-tenths of a second at the speeds indicated, and that the minimum tensions mentioned above can be sustained by the yarn for at least that momentary period of time without appreciable degradation of manifest crimp. In order to more clearly understand the manner in which the yarn is deposited in container 34, reference may also be made to FIG. 2 of the drawings. Cylindrical container 34 is rotated about its vertical axis and guide 28 is reciprocated by shaft 31 between a position substantially adjacent the axis of rotation of container 34 radially outward therefrom to a position substantially adjacent the internal perimeter 35 of container 34. This movement of guide 28 causes the plied yarn 10 to laterally traverse the feed rolls 30 and 32 without losing contact with the peripheral roll surfaces, thus causing the yarn 10 to be deposited in evenly distributed folds throughout the container, and uncompressed except for the weight of the yarn deposited above. As the yarn 10 is thus laid into the container 34 an extremely uncompacted, low-density mass of yarn is formed. Further, due to the manifest crimp formations in the yarn and the bends and turns which are induced in the yarn by the interaction of the motions described in the preceding paragraph, the yarn in the container assumes a highly irregular short-term configuration. That is, in addition to the crimp and deformations made manifest in the yarn by the heat and moisture treatment previously described, additional deformations are created in the yarn as it is deposited by the rolls into the rotating container 34. When the container, which may be on the order of 16 inches in diameter is filled, all operations, including the rotation of the flyer 19 and mandrel 18, can be stopped by an operator who then severs the yarn 10 immediately above container 34 and replaces the filled container 34 with an empty container of like construction. The operator, in accordance with well-known textile practices, can provide "transfer tails" at each end of the length of yarn in a given container, for convenience of subsequent handling. A filled container 34, either separately or with such other filled containers, is then autoclaved under conditions of approximately 240°-270°F in saturated steam for a period which may vary depending upon the exact temperature employed, preferably about 30 minutes. It should be noted that although BCF yarns have been autoclaved at similar temperatures in previously known processes, such processes usually include additional steaming steps at somewhat lower temperatures than those mentioned above. Those additional steps, we surmise, are primarily for the purpose of attempting to redevelop manifest crimp and bulk removed from the yarn in the handling processes preceding autoclaving. When the same BCF yarns are processed according to the procedures outlined herein, however, such additional steaming steps are rendered unnecessary, and the resulting products are still superior in crimp and bulk to the yarns produced by such prior processes. After the autoclave treatment, the plied yarn 10 may be removed from the container 34 by any suitable procedure and used accordingly. When fabricated into carpets, the resulting yarn has been found to have superior bulk, due to a greater degree of crimp and twist which had been permanently set into the yarn in the autoclave. In addition, such yarns differ from previous BCF carpet yarns in that they display, in the final cut-pile carpet, an aesthetically pleasing irregular linear configuration which has also been set into the yarn by the autoclave processing. This irregular configuration, in addition to its aesthetic qualities, further adds to the bulk and "covering power" of the yarn to the extent that yarns produced according to our invention apparently possess approximately 15% more covering power than like yarns of like denier produced according to prior methods. Stated another way, in a cut-pile shag carpet produced from our yarn, for example a typical section containing 12 oz. of yarn per square unit will provide as much covering power as 14 oz. or more of the same denier yarn which was processed according to prior methods. Referring further to FIG. 2, we have found that more than one end of plied yarn 10 may be processed at a given time according to the steps prescribed above, and that both ends may be removed simultaneously from the mandrel 18, also as described above, and deposited in separate containers 34 and 36 by the use of additional guide 29 and feed rolls 38 and another not shown. According to this modification, an additional end of yarn is simply fed from the creel into the flyer 19 and both ends of plied yarn 10 are laid simultaneously upon the mandrel as described previously. Both ends of yarn 10 may also be removed from the mandrel 18 at end 22 and passed through the same guide 27. From that point, as illustrated in FIG. 2, they are separated, each yarn passing to its separate guide, 28 or 29, traversing separate sets of identical feed rolls. When so processing separate ends, care must be maintained to ensure that each end is removed from the mandrel 18 at the same linear speed and is deposited by the feed rolls at the same linear speed. Accordingly, it is most convenient to place the guides 28 and 29 on the same reciprocating shaft 31 and to have the drive rolls turned at the same speed by the same drive shaft 31. As further illustrated in FIG. 3, the surfaces of both feed rolls may both be covered with a rubber or like synthetic material 41, or one roll 32 may be covered with rubber while the other roll has a serrated steel surface 39 for more positive gripping of the yarn 10. Although there exist several types of commercially available apparatus which include rotating mandrels and can be used for the thermal treatment of textile fibers, the type presently preferred by us in the practice of our invention is that designated as the "HBS" machine, manufactured by Eugen Hirschburger, KG of Reutlingen, West Germany, which can be suitably modified and adapted to carry out the procedures specified herein. To the extent not previously explained, the following example of the utilization of our invention should serve to instruct those skilled in the art of the general parameters of speeds, tension, temperatures and other processing conditions that may be employed. First, assuming the use of a 2400 denier BCF yarn, a twist of 2.5 turns per inch in the Z direction is inserted in each of two strands of yarn. The strands are then plied together, receiving a ply twist of 2.5 turns per inch in the S direction. The yarn is then inserted into the HBS machine so that the flyer 19 winds the plied yarn, containing a total of 4800 denier, about the mandrel at a linear rate in excess of 1000 yards per minute. The diameter of the larger end 16 of the mandrel is about 1 meter, the rotational speed of the mandrel is 20 R.P.M., and the speed of the belts 20 is adjusted to about 10 feet per minute to ensure that the yarn wound about the mandrel is evenly deposited, rather than bunched together or superimposed, as discussed previously, The treatment zone of the HBS machine is modified and adapted, also as discussed previously, to apply heat and moisture conditions to the slack and untensioned yarn so as to fully develop its latent crimp characteristics. Feed rolls 32, 30 are rotated at a speed adapted to continuously withdraw the yarn from mandrel 18 at a linear velocity of about 800 yards per minute and the tensions thus developed are immediately relieved as the yarn passes through the feed rolls 32, 30 and is deposited in container 34. The speed of rotation of the container may be on the order of 8 revolutions per minute and a traverse speed of guide 28 may be selected in conjunction with the linear speed of the yarn and the rate of container rotation to ensure even distribution of yarn within the container. Also, the relative speeds of the container rotation, feed roll rotation, and yarn guide traverse may be varied to control the degree of bends and turns in the yarn which contribute to the irregular formations mentioned previously. Autoclave pressure may be selected, of course, depending upon the desired temperatures. Pressures providing treatment temperatures of at least 240°F are preferred. When it is desired to exchange an empty container 34 for a filled container, the apparatus may be stopped for a brief duration without damaging or causing non-uniformity in the yarn 10 which remains in the treatment zone for a longer than usual period of time. Although the foregoing descriptions and example illustrate a preferred embodiment of our invention, it will be apparent to those skilled in the art, that variations are both possible and permissible. Accordingly, such variations as would be obvious to those skilled in the art are intended to be included within the scope of the invention we now claim.
A novel and improved carpet yarn for cut-pile carpets is produced by twisting a strand of yarn having pre-existing latent filament crimp characteristics to a predetermined twist level in a given direction and then plying it with a similar strand or strands having the same amount of twist inserted therein in the same direction. The yarns are plied together, receiving a ply twist essentially equal in amount to the twist in the single strands, but in the opposite direction. The plied yarn is then wound on a rotating mandrel which is also adapted to advance the yarn along the length of the mandrel and through a treatment zone wherein predetermined conditions of heat and moisture are applied to fully develop the latent crimp characteristics of the yarn filaments. The plied yarn is then removed from the opposite end of the mandrel under a minimum tension which is maintained only long enough to remove the yarn from the mandrel and which is immediately relieved by depositing the yarn under no tension in a suitable container for further treatment. The yarn is deposited in such containers in a substantially uniform low density mass wherein linear segments of the yarn are arranged in an irregular short-term configuration which is obtained by rotating the containers while placing the yarn along the radii thereof in a recirpocating fashion. The container of yarn is then positioned in a second treatment zone wherein the yarn is subjected to more severe conditions of heat and moisture adequate to permanently set in the yarn the previously manifested filament crimp characteristics, the yarn twist and ply twist, and the irregular short-term configuration of the plied yarn.
3
BACKGROUND OF THE INVENTION This invention relates to gravity feed tray droppers having rotary head tray dispensers. More specifically, this invention relates to a gravity feed tray dropper which may be quickly and accurately adjusted to any size, shape or lip thickness of trays whether the trays be paper, plastic or metal. The invention has particular utility in dispensing trays such as used in the frozen food packaging industry and will be described in this context. Trays of frozen foods, such as vegetables, sauces, meat dishes, baked goods, pastries, and almost every other variety of food which is susceptible to pre-cooking and freezing is now customarily packaged in shallow draft trays, having perimeter flanges or lips, which can be stacked and fed either singularly or in multiples onto a food conveyor where the trays are filled and sealed. Because trays are made from various materials, and are made in virtually unlimited numbers of shapes and sizes, including circular, rectangular, and all variations inbetween, there has been a long felt need for a tray dropper which does not require a different dispensing head for each different size of tray. Heretofore, rotary dispensing heads have been of the screw type, such as shown in prior art FIG. 1, wherein a screw thread S grips the lip L of a tray T between helical flights S1 and S2. It will be readily appreciated that the number of lip thicknesses which can be accommodated between flights of a particular screw thread is extremely limited. Accordingly, in order to change over from one type of tray to another type of tray, having a different lip thickness, it has been necessary to substitute a dispensing head having a screw thread of a different pitch. This, of course, requires that a wide range of dispensing heads be maintained in stock for changing over from one size tray to another size tray, and also involves considerable labor and down time in making these change overs. Additionally, it has been known for set-up men to wedge the flights of the helical screw threads apart or to hammer them together in order to avoid the down time required to replace the dispensing heads. This has resulted in uneven results, erratic dispensing and has been another cost factor in the utilization of this type of tray dropper. BRIEF DESCRIPTION OF THE INVENTION The subject invention is designed to avoid the problems encountered in the prior art with screw thread type tray droppers. In addition to providing a tray stacking mechanism which is universally adjustable to any size or shape of tray, the screw type dispensing head has been eliminated and replaced with a novel dispensing head. This improved head is instantly adjustable to any lip thickness of any type tray now used in the food processing industry. Instead of relying on a screw thread, which is not adjustable, the subject invention utilizes rotatable discs to support the undersides of the lips of the bottom tray of a stack of trays through a predetermined arc of rotation. Thereafter, tray separating blades, spaced above the lower supporting discs, are adapted to engage the undersides of the lips of a tray second from the bottom of the stack of trays. The tray separating blade holds the stack in place but permits the bottom tray to fall by gravity away from the stack. Thereafter, the tray must be intercepted and guided onto a conveyor by means well known to those skilled in the art, and not a portion of this invention. When the stack has been run out and it is desired to run a different size tray, the tray dropper can be adjusted within a matter of a few seconds by turning easily accessible manual adjustment knobs. These adjustments can be quickly made at any time as required and by an unskilled operator. It is therefore among the objects of this invention to provide a tray dropper which: can receive and dispense an unlimited number of sizes and shapes of trays; can be quickly adjustable by unskilled labor; does not rely on screw thread type dispenser heads; can accommodate trays of unlimited numbers of lip thicknesses; is quickly adjusted to receive trays of any lip thickness and which can be adjusted without shutting down the conveyorized food processing line. Other objects, improved features and advantages of the invention will become apparent from a study of the detailed descriptions of the preferred embodiments described herein and illustrated in the accompanying drawings in which: FIG. 1 is an elevational view of a prior art screw type tray dispenser head; FIG. 2 is an elevational view of a preferred embodiment of the invention; FIG. 3 is a plan view of the preferred embodiment of the invention shown in FIG. 2; FIG. 4 is an elevational view taken along the line 4--4 of FIG. 2; FIG. 5 is a plan view partially in section of FIG. 4; FIG. 6 is an elevational view taken along line 6--6 of FIG. 5; FIG. 7 is an elevational view in section of a preferred embodiment of the tray dispenser taken along the line 7--7 of FIG. 5; FIG. 8 is a plan view taken along the line 8--8 of FIG. 7; FIG. 9 is a plan view taken along the line 9--9 of FIG. 7; FIG. 10 is a fragmentary elevational view taken along the line 10--10 of FIG. 9; FIG. 11 is a plan view similar to FIG. 8 but rotated 180°; FIG. 12 is a plan view similar to FIG. 9 but rotated 180°; and, FIG. 13 is a fragmentary elevational view, taken along the line 13--13 of FIG. 12, similar to FIG. 10 but rotated 180°. DETAILED DESCRIPTION OF THE INVENTION Reference is now made to FIGS. 2 and 3 wherein are shown elevational and plan views of a preferred embodiment 10 of the invention. A frame 12 supports a drive motor 14 and a gear box 16 which is drivingly connected to gear box sprockets 18 and 19 by means of drive chain 20. Gear box 22 is supported on a pair of gear box support plates 24 and 26. A second gear box 28 is also mounted on gear box support plates 24 and 26 and is positioned over adjusting slots 30. Hand knobs 31 secure gear box 28 to support plates 24 and 26 through slots 30. When loosened, hand knobs 31 permit gear box 28 to be shifted either to the right or to the left relative to gear box 22, depending on the size of trays required to be dispensed from the tray stack support rods 32. Support rods 32 are universally adjustable in any horizontal direction by means of support rod adjusting bars 34. It will be noted that each adjusting bar 34 is provided with an adjusting slot 36 which provides for the universal horizontal shifting of rods 32 upon loosening of cap screws 38. Sprocket 19 rotates a drive shaft in gear box 22 which in turn rotates tray dispenser heads 40 and 42, as will be described more fully hereinafter. Sprocket 19 also, by means of gear box 46, rotates drive shaft 44. Gear box 47 by gear means, translates the rotation of drive shaft 44 to drive a shaft in gear box 28 which rotates tray dispenser heads 48 and 50. It will be noted that drive shaft 44 is provided with a keyway 52 substantially along its entire longitudinal axis so that gear box 28 may be driven at any position along adjustment slots 30 of gear box support plates 24 and 26. Referring to FIGS. 4, 5 and 6, it will be seen that sprocket 19 sequentially drives the gears in gear box 46 drive shaft 54, gears 56, 58, 60 and 62, and tubular shafts 64 and 66 respectively. Referring to FIG. 7, therein is shown in section a tray dispensing head 40 comprising a cylindrical block 70 having a vertical minor bore 72 in communication with a major vertical bore 74. The tubular shaft 66 is received within the minor bore 72 and extends downwardly into major bore 74. Tubular shaft 66 is secured for rotation with the cylindrical block 70 by means of set screw 76. The tubular shaft 66 also projects upwardly through the top plate 76 of gear box 22 and is secured thereto by bushing 78 and spring clip 80. A rod 82, threaded at opposite ends 84 and 86, is fitted concentrically within tubular shaft 66. The upper threaded end 84 has a knurled adjusting knob 88 threaded thereon to make abutting contact with the upper edge 90 of tubular shaft 66. The lower threaded end 86 of rod 82 is threadedly engaged with tray dispensing disc 92. A helical spring 94 is received within major bore 74 to bias tray dispensing disc 92 downwardly away from cylindrical block 70. Spring 94 also holds adjusting knob 88 in firm bearing contact with surface 90 of tubular shaft 66. It will be apparent, therefore, that clockwise rotation of adjusting knob 88, as viewed in FIG. 5, will compress coil spring 94 to draw tray dispensing disc 92 closer to cylindrical block 70, or, upon counterclockwise rotation of adjusting knob 88, tray dispensing disc 92 may be shifted downwardly away from cylindrical block 70. A tray separator blade 96 is machined to project horizontally from the lower surface of cylindrical block 70. FIGS. 8, 9 and 10 will now be discussed in conjunction with the function of dispensing head 40. Referring first to FIG. 8, it will be seen that bottom tray dispensing disc 92 is substantially circular in configuration but is truncated along edge 98. As indicated by arrow 100, this disc rotates in a counterclockwise direction. Tray dispensing blade 96 comprises a partially circular horizontal flange extension of bottom surface 102. Blade 96 passes arcuately about the periphery 104 of cylindrical block 70, starting with leading edge 106, 240° to trailing edge 108. A portion of blade 96, from leading edge 106 to intermediate edge 110, is an inclined plane 112, as best shown in FIG. 10, to form a tray lip separating wedge. For purposes of explanation, assume that FIG. 10 represents a position of rest of dispensing head 40 before the tray dropper is actuated. It will be seen that a stack of trays T1, T2 and T3 are provided with lips L1, L2 and L3 respectively. It will be particularly noted that lip L1 is resting upon the circular periphery 114 of bottom tray dispensing disc 92. It will also be observed that leading edge 106 of wedge surface 112 makes no contact with the stacked trays at this time. Referring now to FIGS. 11, 12 and 13, it may be assumed that the tray dropper has been actuated and that dispenser head 40 has been rotated 180°. It will be seen, from observing FIGS. 11, 12 and 13, that periphery 114 of disc 92 has been rotated out of engagement with the underside of lip L1 of tray T1. Accordingly, tray T1 is free to drop by gravity to a conveyor where further processing will occur. It will also be noted, that the underside of lip L2 of tray T2 has been wedged upwardly by wedge surface 112 of blade 96 and is now supported by the upper surface 116 of tray separator blade 96. Upon another 180° revolution of bottom disc 92 and blade 96, the outer periphery 114 of bottom plate 92 will now support the under surface of lip L2, similar to lip L1 of FIG. 10, prior to separation of lip L2 from lip L3 by wedge 112 of blade 96. In the manner described, by rotation of dispensing head 40, a bottom tray is separated from the stack of trays every revolution of the dispensing head. It will also be observed that the thickness of the lips L1, L2 and L3 may be readily accommodated between bottom disc 92 and blade 96 by simple rotational adjustment of knurled adjusting knob 88. Thus, if a series of lips should run oversize or undersize it is not necessary to shut down the food processing line to adjust for this unexpected thickness inasmuch as a simple adjustment of knurled adjusting knob 86 will quickly make the necessary accommodation to a change in thickness of the lips. It has been found that by rotating dispensing heads 40 and 42 so that discs 92 and blades 96 first engage a tray lip near the lips center and then rotate outwardly toward the corners of the tray, fewer tray mis-feeds occur. To rotate heads 40 and 42 so as to first engage a tray lip close to the corners of a tray, mis-feeds are more likely to occur because of excess tray material which overlaps at the tray corners, causing hang-ups. Thus, as shown in FIG. 3, dispensing heads 42 and 48 rotate clockwise and dispensing heads 40 and 50 rotate counterclockwise. It will also be understood that whereas four dispensing heads are shown in the preferred embodiment of the invention, there are certain circumstances in which other numbers of dispensing heads may be more efficiently utilized. Thus, for instance, it is conceivable that with certain types of trays only two dispensing heads are required, and whereas with other types of trays three to six dispensing heads may be required. However, for most sizes of trays presently being commercially utilized, it has been found that the use of four dispensing heads is the most useful embodiment of the invention. As is apparent from the foregoing description, a tray dropper is provided which is quickly and accurately adjusted to accommodate all known sizes of trays presently in commercial use, and this adjustment does not require the skilled services of a set-up man. Unskilled labor with the briefest of indoctrination can be taught to make the necessary adjustments to keep the tray dropper operating efficiently without interruption. It will be further understood that the above described embodiments of the invention have been set forth for the purpose of illustration only. Additional embodiments, modifications and improvements can be readily anticipated by those skilled in the art based on a reading and study of the present disclosure. Such additional embodiments, modifications and improvements may be fairly presumed to be within the spirit, scope and purview of the invention as defined by the subtended claims.
A gravity feed rotary head tray dropper is provided which may be universally adjusted for different tray sizes, shapes and lip thicknesses. The device includes a rotatable blade to separate the bottom tray from a stack of trays and a rotatable tray support disc to hold the stack of trays in position between tray separations. The rotatable tray support disc is positioned beneath the rotatable blade and is vertically adjustable to accommodate tray lips of varying thicknesses.
1
[0001] This application claims priority to U.S. Provisional Application No. 61/678,800 filed Aug. 2, 2012, which is incorporated herein by reference. [0002] This invention was made with Government support under contract CA 124832 awarded by the National Institutes of Health. The Government has certain rights in this invention. FIELD OF THE INVENTION [0003] The invention relates to peptides useful targets for generating immune responses against cancer cells which express the type III mutant epidermal growth factor receptor. The invention relates to vaccines and methods of using the vaccines in anti-cancer treatments and regimens. BACKGROUND OF THE INVENTION [0004] Epidermal growth factor receptor (also referred to as EGFR; ErbB-1; and HER1 in humans) is a cell-surface receptor that is activated when it binds to specific ligands, such as epidermal growth factor (EGF) and transforming growth factor α (TGFα). The cDNA sequence corresponding to normal EGF receptor is disclosed in Ullrich et al. Nature 1984 309, 418-425. [0005] Wong et al., Proc Natl Acad Sci USA 1992, 89, 2965-2969 and PCT Application Serial No. PCT/US90/04489 report the genetic alterations associated with rearrangements or deletions of the gene encoding EGFR in five malignant gliomas including the variant EGFR referred to as the Type III mutant EGF receptor (hereinafter EGFRvIII) which is the translation product of a splice variant of the EGFR gene corresponding to a deletion between nucleotides 275-1075 in the EGF receptor cDNA which corresponds to a deletion of the portion of coding sequence encoding the extracellular domain of the receptor corresponding to exons 2 through 7, such that exon 1 is joined to exon 8. The in-frame splice junction formed by the deletion includes a codon that encodes a glycine residue where the two sequences are joined. This glycine residue coding sequence is not found at the corresponding location in either the normal exon 1 coding sequence or the normal exon 8 coding sequence of the normal EGFR gene. The EGFRvIII deletion results in the fusion of what were ordinarily distant sequences to generate a mutated sequence that encodes a novel peptide sequence at this fusion junction. [0006] EGFRvIII is the most frequent, naturally occurring mutant EGFR in human tumors and is particularly prevalent in the brain tumor called glioblastoma multiforme. EGFRvIII has been reported to be present in 56% of glioblastoma tumors and 16% of non-small cell carcinomas of the lung. Moscatello et al. Cancer Res. 1995, 55, 5536-5539 reports that it has also been found to be present in 78% of breast cancers. EGFRvIII was therefore identified as a potentially ideal tumor target because the sequence was not found in any normal tissue. [0007] The deletion corresponding to exons 2 through 7 in which exon 1 is joined to exon 8 is an in frame alteration that creates a codon for a novel glycine at the junction. The amino terminus of the resulting EGFRvIII protein is characterized by the amino acid sequence LEEKKGNYVVTDH, SEQ ID NO:1 where the L represents the first amino acid of the mature protein, and the G is the result of the exon 1 to 8 fusion. [0008] Vaccines comprising peptides corresponding to the EGFRvIII junction have been used to prevent or induce regression of tumors that overexpress EGFRvIII in animal models. The formulation of the vaccine is using the peptide LEEKKGNYVVTDHC SEQ ID NO:2 (in which the terminal cysteine has been added for conjugation purposes) conjugated to immune stimulatory molecule, KLH. The glycine was thought to be a key feature for the recognition of this peptide as foreign by the immune system because it is novel, although without any direct experimental evidence. This particular peptide:KLH conjugate vaccine has now been used in a Phase II clinical trial for glioblastoma where it was shown median survival of 26 months as compared to 15 months for matched historical controls. [0009] Peptides based upon the protein sequence encoded by the splice junction have been described in U.S. Pat. Nos. 6,224,868, 5,212,290, 5,401,828, 5,710,010, 5,814,317, 5,981,725, 6,127,126 and 6,455,498. Additionally, these patents disclose peptides conjugated to carriers such as keyhole limpet hemocyanin (KLH) and their use as vaccines. Sampson et al. US Publication No. 20090220551 discloses EGFRvIII peptides with different C termini and generally discloses methods of using the peptides as adjuvant therapy in cancer treatment protocols. [0010] Heimberger and Sampson, Expert Opin Biol Ther. 2009 August; 9(8): 1087-1098 disclose results from three different clinical trials using an EGFRvIII-KLH conjugate which comprises the EGFRvIII peptide having SEQ ID NO:2 conjugated to KLH to treat patients with glioblastoma. In one trial, patients first had tumors resected followed by radiation therapy. Thereafter, dendritic cells (DCs) were isolated from patients, pulsed with EGFRvIII-KLH conjugate and reintroduced into patients as autologous DCs. In a second trial, patients had tumors resected followed by radiation therapy and then EGFRvIII-KLH conjugate was administered directly to the patients by injection. In the third trial, patients had tumors resected followed by radiation therapy after which EGFRvIII-KLH conjugate was administered directly to the patients by injection while patients underwent chemotherapy using temozolomide (TMZ). In each clinical trial, improvements in time to progress and overall survival were observed compared to historical time to progress and overall survival statistics. [0011] The current vaccine, while showing a significant prolongation in survival, is not curative. Clearly, patients are desirous of treatments that offer the best possible chance at long term survival. As such, there remains a need to provide improved EGFRvIII vaccines to enhance survival. There remains a need for improved compositions and therapies useful to improve clinical outcomes in patients diagnosed with cancer that expresses EGFRvIII. SUMMARY OF THE INVENTION [0012] The present invention relates to vaccine compositions that comprise a prophylactically or therapeutically effective amount of a peptide conjugated to a carrier, having the formula: [0000] L1-E2-Glu-Lys-Lys-Xaa6-N7-Y8-V9-V10-T11-D12-H13-C14-Carrier [0000] wherein L1 is absent or Leu; E2 is absent or Glu; Xaa6 is Ala, Arg, Asn, Asp, Cys, Gln, Glu, His, Ile, Leu, Lys, Met, Phe, Pro, Ser, Thr, Trp, Tyr or Val; N7 is absent or Asn; Y8 is absent or Tyr; V9 is absent or Val; V10 is absent or Val; T11 is absent or Thr; D12 is absent or Asp; H13 is absent or His; C14 is Cys or a linking moiety that can link the peptide to Carrier. [0024] In some embodiments, Xaa6 is Ala, Val or Pro. In some embodiments, L1-E2-Glu-Lys-Lys-Xaa6-N7-Y8-V9-V10-T11-D12-H13-C14 comprises at least 4 amino acids, at least 5 amino acids, at least 6 amino acids, at least 7 amino acids, at least 8 amino acids, at least 9 amino acids, at least 10 amino acids, at least 11 amino acids, at least 12 amino acids, at least 13 amino acids or at least 14 amino acids. [0025] In some embodiments, the present invention provides vaccine compositions that comprise a prophylactically or therapeutically effective amount of a peptide conjugated to a carrier, having the formula: [0000] α-Glu-Lys-Lys-Xaa-β [0000] wherein α is absent, acyl, Leu-Glu; Glu; or Leu; Xaa is Ala, Arg, Asn, Asp, Cys, Gln, Glu, His, Ile, Leu, Lys, Met, Phe, Pro, Ser, Thr, Trp, Tyr or Val; and β is absent, Asn, Asn-Tyr, Asn-Tyr-Val, Asn-Tyr-Val-Val, Asn-Tyr-Val-Val-Thr (SEQ ID NO:9), Asn-Tyr-Val-Val-Thr-Asp (SEQ ID NO:10), Asn-Tyr-Val-Val-Thr-Asp-His (SEQ ID NO:11), Asn-Tyr-Val-Val-Thr-Asp-His-Cys (SEQ ID NO:12); Tyr, Tyr-Val, Tyr-Val-Val, Tyr-Val-Val-Thr (SEQ ID NO:13), Tyr-Val-Val-Thr-Asp (SEQ ID NO:14), Tyr-Val-Val-Thr-Asp-His (SEQ ID NO:15), Tyr-Val-Val-Thr-Asp-His-Cys (SEQ ID NO:16), Val, Val-Val, Val-Val-Thr, Val-Val-Thr-Asp (SEQ ID NO:17), Val-Val-Thr-Asp-His (SEQ ID NO:18), Val-Val-Thr-Asp-His-Cys (SEQ ID NO:19), Val-Thr, Val-Thr-Asp, Val-Thr-Asp-His (SEQ ID NO:20), Val-Thr-Asp-His-Cys (SEQ ID NO:21), Thr, Thr-Asp, Thr-Asp-His, or Thr-Asp-His-Cys (SEQ ID NO:22), Asp, Asp-His, Asp-His-Cys, His, His-Cys, or Cys. [0029] In some embodiments, the present invention provides a vaccine composition that comprise a prophylactically or therapeutically effective amount of a peptide conjugated to a carrier in which the peptide has the amino acid sequence selected from the group consisting of: SEQ ID NO:6 (Peptide A), SEQ ID NO:7 (Peptide V), and SEQ ID NO:8 (Peptide P). [0030] In some embodiments, the present invention provides a vaccine composition that comprises a prophylactically or therapeutically effective amount of a peptide conjugated to a carrier is selected from the group consisting of: SEQ ID NO: 6 conjugated to KLH, SEQ ID NO:7 conjugated to KLH, and SEQ ID NO:8 conjugated to KLH. [0031] The present invention further comprises methods of inhibiting formation or growth of tumors bearing a naturally occurring Type III mutant EGF receptor in a human subject. The methods comprise administering to the subject a vaccine provided herein. [0032] The present invention further comprises methods of inducing regression of an existing tumor bearing a naturally occurring Type III mutant EGF receptor in a human subject. The methods comprise administering to the subject a vaccine provided herein. [0033] The present invention further comprises methods of immunizing a human subject who has been identified as being at an elevated risk for developing a tumor comprising tumor cells expressing type III mutant EGF receptors against tumors bearing type III mutant EGF receptors. The methods comprise administering to the subject a vaccine provided herein. [0034] The present invention further comprises methods of treating a human subject who has one or more tumors bearing type III mutant EGF receptors. In some embodiments, the methods comprise the steps of removing at least one tumor bearing type III mutant EGF receptors and/or administering a therapeutically effective amount of radiation and/or administering a therapeutically effective amount of one or more anticancer chemotherapeutics, and additionally administering to the subject a vaccine provided herein. In some embodiments, the methods comprise the steps of tumor is not removed prior to administering a therapeutically effective amount of radiation and/or administering a therapeutically effective amount of one or more anticancer chemotherapeutics, and additionally administering to the subject a vaccine provided herein. [0035] The present invention also provides isolated peptides used in the vaccine provided herein. BRIEF DESCRIPTION OF THE FIGURE [0036] FIG. 1 shows survival over time data from experiments discussed in Example 1. DETAILED DESCRIPTION OF THE INVENTION [0037] Vaccines which comprise a peptide sequence similar to the fusion junction of EGFRvIII including a substitution of the glycine residue formed at the splice junction of the EGFRvIII receptor are provided. The peptides used in the vaccine are sufficiently similar to EGFRvIII such that an immune response generated against the peptides cross-reacts to EGFRvIII expressed on cancer cells. Generally, the peptides contain portions similar to each of the sequences from the two formerly distant portions of the normal EGF receptor. [0038] It is preferred that the vaccine comprises a peptide conjugated to a hapten carrier such as keyhole limpet hemocyanin (KLH), bovine serum albumin (BSA) or human serum albumin (HAS). [0039] In some embodiments, the vaccines comprise a peptide selected from the group consisting of LEEKKANYVVTDH (SEQ ID NO:3), LEEKKVNYVVTDH (SEQ ID NO:4), and LEEKKPNYVVTDH (SEQ ID NO:5). In some embodiments, peptides comprise a C-terminal cysteine. In some embodiments, the vaccines comprise a peptide selected from the group consisting of LEEKKANYVVTDHC (SEQ ID NO:6), LEEKKVNYVVTDHC (SEQ ID NO:7), and LEEKKPNYVVTDHC (SEQ ID NO:8). In some embodiments, the vaccines comprise a peptide linked to KLH and are selected from the group consisting of: LEEKKANYVVTDHC:KLH (SEQ ID NO:6 conjugated to keyhole limpet hemocyanin), LEEKKVNYVVTDHC:KLH (SEQ ID NO:7 conjugated to keyhole limpet hemocyanin), and LEEKKPNYVVTDHC:KLH (SEQ ID NO:8 conjugated to keyhole limpet hemocyanin) [0040] Other peptides based upon the EGFRvIII sequence with substitutions of the splice junction glycine may also be used in the vaccines and methods. In some embodiments, peptides, which are optionally linked to a carrier such as for example KLH, BSA or HAS, have the formula: [0000] α-Glu-Lys-Lys-Xaa-β  Formula I [0000] wherein α is absent, acyl, Leu-Glu; Glu; or Leu; Xaa is Ala, Arg, Asn, Asp, Cys, Gln, Glu, His, Ile, Leu, Lys, Met, Phe, Pro, Ser, Thr, Trp, Tyr or Val; and β is absent, Asn, Asn-Tyr, Asn-Tyr-Val, Asn-Tyr-Val-Val, Asn-Tyr-Val-Val-Thr (SEQ ID NO:9), Asn-Tyr-Val-Val-Thr-Asp (SEQ ID NO:10), Asn-Tyr-Val-Val-Thr-Asp-His (SEQ ID NO:11), Asn-Tyr-Val-Val-Thr-Asp-His-Cys (SEQ ID NO:12); Tyr, Tyr-Val, Tyr-Val-Val, Tyr-Val-Val-Thr (SEQ ID NO:13), Tyr-Val-Val-Thr-Asp (SEQ ID NO:14), Tyr-Val-Val-Thr-Asp-His (SEQ ID NO:15), Tyr-Val-Val-Thr-Asp-His-Cys (SEQ ID NO:16), Val, Val-Val, Val-Val-Thr, Val-Val-Thr-Asp (SEQ ID NO:17), Val-Val-Thr-Asp-His (SEQ ID NO:18), Val-Val-Thr-Asp-His-Cys (SEQ ID NO:19), Val-Thr, Val-Thr-Asp, Val-Thr-Asp-His (SEQ ID NO:20), Val-Thr-Asp-His-Cys (SEQ ID NO:21), Thr, Thr-Asp, Thr-Asp-His, or Thr-Asp-His-Cys (SEQ ID NO:22), Asp, Asp-His, Asp-His-Cys, His, His-Cys, or Cys. In some embodiments a carrier is optionally linked to a terminal residue such as Cys and if present the carrier is preferably a hapten. In some embodiments, the carrier is KLH, BSA or HSA. [0044] In some embodiments, the vaccines comprise compounds which are optionally linked to a carrier such as for example KLH, BSA or HAS and have the formula: [0000] L1-E2-Glu-Lys-Lys-Xaa6-A7-Y8-V9-V10-T11-D12-H13-C14-Carrier  Formula II; [0000] wherein L1 is absent or Leu; E2 is absent or Glu; Xaa6 is Ala, Arg, Asn, Asp, Cys, Gln, Glu, His, Ile, Leu, Lys, Met, Phe, Pro, Ser, Thr, Trp, Tyr or Val; N7 is absent or Asn; Y8 is absent or Tyr; V9 is absent or Val; V10 is absent or Val; T11 is absent or Thr; D12 is absent or Asp; H13 is absent or His; C14 is Cys or a linking moiety that can link the peptide to Carrier; and Carrier is optional and if present is preferably a hapten. In some embodiments, the carrier is KLH, BSA or HSA. [0057] In some embodiments the peptide of the vaccine has Formula II wherein L1-E2-Glu-Lys-Lys-Xaa6-N7-Y8-V9-V10-T11-D12-H13-C14 and the vaccine comprises at least 4 amino acids, at least 5 amino acids, at least 6 amino acids, at least 7 amino acids, at least 8 amino acids, at least 9 amino acids, at least 10 amino acids, at least 11 amino acids, at least 12 amino acids, at least 13 amino acids or at least 14 amino acids. [0058] In some embodiments, two or more of L1, E2, N7, Y8, V9, V10, T11, D12, H13 and C14 are absent. In some embodiments, L1 and E2 are absent. In some embodiments, L1 and N7 are absent. In some embodiments, L1 and Y8 are absent. In some embodiments, L1 and V9 are absent. In some embodiments, L1 and V10 are absent. In some embodiments, L1 and T11 are absent. In some embodiments, L1 and D12 are absent. In some embodiments, L1 and H13 are absent. In some embodiments, L1 and C14 are absent. In some embodiments, E2 and N7 are absent. In some embodiments, E2 and Y8 are absent. In some embodiments, E2 and V9 are absent. In some embodiments, E2 and V10 are absent. In some embodiments, E2 and T11 are absent. In some embodiments, E2 and D12 are absent. In some embodiments, E2 and H13 are absent. In some embodiments, E2 and C14 are absent. In some embodiments, N7 and Y8 are absent. In some embodiments, N7 and V9 are absent. In some embodiments, N7 and V10 are absent. In some embodiments, N7 and T11 are absent. In some embodiments, N7 and D12 are absent. In some embodiments, N7 and H13 are absent. In some embodiments, N7 and C14 are absent. In some embodiments, Y8 and V9 are absent. In some embodiments, Y8 and V10 are absent. In some embodiments, Y8 and T11 are absent. In some embodiments, Y8 and D12 are absent. In some embodiments, Y8 and H13 are absent. In some embodiments, Y8 and C14 are absent. In some embodiments, V9 and V10 are absent. In some embodiments, V9 and T11 are absent. In some embodiments, V9 and D12 are absent. In some embodiments, V9 and H13 are absent. In some embodiments, V9 and C14 are absent. In some embodiments, V10 and T11 are absent. In some embodiments, V10 and D12 are absent. In some embodiments, V10 and H13 are absent. In some embodiments, V10 and C14 are absent. In some embodiments, T11 and D12 are absent. In some embodiments, T11 and H13 are absent. In some embodiments, T11 and C14 are absent. In some embodiments, D12 and H13 are absent. In some embodiments, D12 and C14 are absent. In some embodiments, H13 and C14 are absent. In some embodiments, three or more of L1, E2, N7, Y8, V9, V10, T11, D12, H13 and C14 are absent. In some embodiments, four or more of L1, E2, N7, Y8, V9, V10, T11, D12, H13 and C14 are absent. In some embodiments, five or more of L1, E2, N7, Y8, V9, V10, T11, D12, H13 and C14 are absent. In some embodiments, six or more of L1, E2, N7, Y8, V9, V10, T11, D12, H13 and C14 are absent. In some embodiments, seven or more of L1, E2, N7, Y8, V9, V10, T11, D12, H13 and C14 are absent. In some embodiments, eight or more of L1, E2, N7, Y8, V9, V10, T11, D12, H13 and C14 are absent. In some embodiments, nine or more of L1, E2, N7, Y8, V9, V10, T11, D12, H13 and C14 are absent. In some embodiments, each of L1, E2, N7, Y8, V9, V10, T11, D12, H13 and C14 are absent. Xaa may be Ala, Arg, Asn, Asp, Cys, Gln, Glu, His, Ile, Leu, Lys, Met, Phe, Pro, Ser, Thr, Trp, Tyr or Val. [0059] The manufacture of peptides is well known. Automated peptide synthesizers may be employed to produce the peptides using techniques that are well known to those having ordinary skill in the art. One having ordinary skill in the art can generate a nucleic acid molecule that encodes a peptide or a protein comprising a peptide and insert it into an expression vector using standard techniques and readily available starting materials. The cloning and expression of proteins is well known as is their purification using for example immunoaffinity, charge or size exclusion. [0060] In some embodiments, the peptide may be linked to a carrier or haptenized to increase immunogenicity. In some cases, the haptenization is the conjugation of a larger molecular structure to the peptide. Haptenization is well known and can be readily performed. Haptenization methods which may be adapted to be used to prepare haptenized peptides include those described in the following U.S. patents which are each incorporated herein by reference: U.S. Pat. No. 5,037,645 issued Aug. 6, 1991 to Strahilevitz; U.S. Pat. No. 5,112,606 issued May 12, 1992 to Shiosaka et al.; U.S. Pat. No. 4,526,716 issued Jul. 2, 1985 to Stevens; U.S. Pat. No. 4,329,281 issued May 11, 1982 to Christenson et al.; and U.S. Pat. No. 4,022,878 issued May 10, 1977 to Gross. Peptide vaccines and methods of enhancing immunogenicity of peptides which may be adapted to modify peptides are also described in Francis et al. 1989 Methods of Enzymol. 178:659-676, which is incorporated herein by reference. Sad et al. 1992 Immunolology 76:599-603, which is incorporated herein by reference, teaches methods of making immunotherapeutic vaccines by conjugating gonadotropin releasing hormone to diphtheria toxoid. Peptides may be similarly conjugated to produce an immunotherapeutic vaccine of the present invention. MacLean et al. 1993 Cancer Immunol. Immunother. 36:215-22.2, which is incorporated herein by reference, describes conjugation methodologies for producing immunotherapeutic vaccines which may be adaptable to produce an immunotherapeutic vaccine of the present invention. The hapten is keyhole limpet hemocyanin which may be conjugated to a peptide. [0061] Pharmaceutical formulations comprising peptides and conjugated peptides may be routinely formulated by one having ordinary skill in the art. Suitable pharmaceutical formulations and components are described in Remington's Pharmaceutical Sciences, A. Osol, a standard reference text in this field, which is incorporated herein by reference. In some embodiments, for example, the vaccine can be formulated as a solution, suspension, emulsion or lyophilized powder in association with a pharmaceutically acceptable vehicle. Examples of such vehicles are water, saline, Ringer's solution, dextrose solution, and 5% human serum albumin. Liposomes and nonaqueous vehicles such as fixed oils may also be used. The vehicle or lyophilized powder may contain additives that maintain isotonicity (e.g., sodium chloride, mannitol) and chemical stability (e.g., buffers and preservatives). An injectable composition may comprise the peptide or conjugated peptide in a diluting agent such as, for example, sterile water, electrolytes/dextrose, fatty oils of vegetable origin, fatty esters, or polyols, such as propylene glycol and polyethylene glycol. [0062] The vaccines may also comprise an adjuvant. Adjuvants useful in vaccine are well known to those of skill in the art, thus, selection of an appropriate adjuvant can be performed routinely by one of skill in the art upon this disclosure. Examples of useful adjuvant include, but are not limited to, complete and incomplete Freund's, mineral gels such as aluminum hydroxide, surface active substances such as lysolecithin, pluronic polyols, polyanions, peptides and oil emulsions. [0063] In some embodiments, the vaccine is an injectable composition that is sterile, pyrogen free, formulated to be isotonic and free of particulates. The standards of purity required for injectable compositions are well known as are the production and purification methods used to prepare injectable compositions. [0064] The vaccines may be administered by any means that enables the immunogenic agent to be presented to the body's immune system for recognition and induction of an immunogenic response. Pharmaceutical injectable compositions may be administered parenterally, i.e., intravenous, subcutaneous, intramuscular. In some embodiments, pharmaceutical vaccine compositions may be administered intranasally or to tissue in the oral cavity such as by administration sublingually or to buccal tissue. [0065] Dosage varies depending upon known factors such as the pharmacodynamic characteristics of the particular agent, and its mode and route of administration; age, health, and weight of the recipient; nature and extent of symptoms, kind of concurrent treatment, frequency of treatment, and the effect desired. An amount of immunogen is delivered to induce a protective or therapeutically effective immune response. Those having ordinary skill in the art can readily determine the range and optimal dosage by routine methods. [0066] The vaccines can be used to treat or prevent tumors that express EGFRvIII. Examples of tumor types that are known to express EGFRvIII include but are not limited to glioblastoma, pediatric brain tumors, non-small cell carcinoma of the lung, ovarian tumors, prostate tumors, head and neck cancers, and breast tumors among several others. In some embodiments, EGFRvIII expression may be confirmed prior to treatment by in vitro detection of EGFRvIII expression in patient samples, in vitro evaluation of patient samples including tumor sample or other samples containing tumor cells, in vivo imaging or detection of EGFRvIII expression or other means to indicate that the patient's cancer expresses EGFRvIII. [0067] In some embodiments, treatment with vaccines is part of a comprehensive treatment protocol which includes surgical resection and/or radiation therapy and/or chemotherapy with anti-cancer compounds, antibodies and the like. In some embodiments, vaccines are administered following resection. In some embodiments, vaccines are administered following radiation therapy. In some embodiments, vaccines are administered together with chemotherapy. In some embodiments, vaccines are administered together with chemotherapy using temozolomide. In some embodiments, vaccines are administered together with chemotherapy using anti-EGFR antibodies. [0068] In some embodiments, vaccines are delivered ex vivo to cells which are then administered to the individual. In some embodiment, the vaccines are delivered as part of an autologous cell therapy protocol whereby cells removed from an individual as treated ex vivo with vaccine and reintroduced in the individual. Dendritic cells and other immune cells may be treated ex vivo and used in cell therapy/vaccine protocols. [0069] The vaccines can be used as antigen targets for producing antibodies including monoclonal antibodies, using any technique which provides for the production of antibodies by continuous cell line in culture. Such techniques are well known to those of skill in the art and include, but are not limited to, the hybridoma technology originally described by Kohler and Milstein, Nature 1975, 256, 495-497, the human B-cell hybridoma technique described by Kosbor et al., Immunology Today 1983, 4, 72 and the EBV-hybridoma technique described by Cole et al., Monoclonal Antibodies and Cancer Therapy, Alan R. Liss, Inc., pp 77-96. Antibodies, including monoclonal antibodies, humanized antibodies, and human antibodies can be prepared and used as therapeutics. [0070] The following nonlimiting examples are provided to further illustrate the invention. EXAMPLES Example 1 [0071] Studies were undertaken to improve the anti-tumor efficacy of the EGFRvIII vaccine. Vaccines comprising EGFRvIII peptide variations produced and tested show greatly increased tumor regression following vaccination. These EGFRvIII peptide variations included substitutions in the splice junction glycine. [0072] A structural study of the EGFRvIII peptide bound to a single chain recombinant antibody revealed that the novel glycine makes no contacts with the antibody (Landry et al J Mol Biol. 2001; 308(5):883-93). Thus, this glycine may not be essential for immune recognition. However, the glycine might be important for the flexibility of the peptide as the structure of this peptide makes a turn at this amino acid. [0073] Since the glycine was not essential for immune recognition but might contribute to structure, peptides vaccines were prepared with amino acid substitutions for the glycine to determine if such modification enhance the anti-tumor effects of the peptide vaccine. The peptides tested were: [0000] Peptide A (SEQ ID NO: 6) LEEKKANYVVTDHC Peptide V (SEQ ID NO: 7) LEEKKVNYVVTDHC Peptide P (SEQ ID NO: 8) LEEKKPNYVVTDHC. Peptide no G (SEQ ID NO: 9) LEEKKNYVVTDHC. Peptide G (SEQ ID NO: 2) LEEKKGNYVVTDHC. [0074] The peptides were conjugated to KLH to produce the following conjugated peptide vaccines. Peptide A:KLH Peptide V:KLH Peptide P:KLH Peptide no G:KLH Peptide G:KLH [0080] The conjugated peptide vaccines were tested in tumor regression experiments and survival results were compared among animals treating with one of the conjugated peptide vaccines or KLH only. The data is shown in Table 1. Peptide A:KLH, Peptide V:KLH, and Peptide P:KLH each showed better survival rates than those observed with the original conjugated peptide vaccine Peptide G:KLH. Peptide no G:KLH was less effective than Peptide G:KLH which was only slightly more effective than KLH only. [0000] TABLE 1 Conjugated vaccine Survival Peptide A: KLH 90% Peptide V: KLH 70% Peptide P: KLH 70% Peptide no G: KLH 30% Peptide G: KLH 55% KLH only 47% [0081] These vaccines appear to be faster acting, i.e., induce tumor regression in a shorter period of time. They also appear to be more effective, i.e., more animals showed regression using vaccines having G substitutions than with Peptide G:KLH. Thus the data indicate that the central glycine, thought to be essential for activity, can be modified to give superior vaccines. [0082] Additional experiments were performed repeating the experiments described above. Following completion of additional experiments the data was compiled and set forth in Table 2, which shows the overall survival data and total number of animals. Survival over time is shown in FIG. 1 . In the overall survival data, use of each of Peptide A:KLH, Peptide V:KLH and Peptide P:KLH resulted in a higher percent survival compared to the use of Peptide G:KLH and Peptide G:KLH was moderately more effective than KLH only. [0000] TABLE 2 Conjugated vaccine Survival Total # of animals Peptide A: KLH 80% 20 Peptide V: KLH 70% 20 Peptide P: KLH 65% 20 Peptide no G: KLH 30% 10 Peptide G: KLH 43% 49 KLH only 32% 37 [0083] For all experiments, the peptides were synthesized with the sequence as indicated with the cysteine at the carboxy terminus added for the purposes of conjugation. Peptides were then conjugated at a 1:1 w/w ratio to maleimide activated Keyhole Limpet Hemocyanin (KLH) for 24 hours. Following conjugation, the peptide:KLH conjugate was dialyzed against PBS to remove unconjugated peptide [0084] NIH Swiss mice were inoculated subcutaneously in the right hand flank with 2×10 6 HC2 20d2/c cells, an NIH-3T3 cell line engineered to overexpress EGFRvIII. This cell line has been previously used to study anti-tumor responses to SEQ ID NO:2 conjugated to KLH (Moscatello et al., Cancer Res. 57:1419). On the 7 th day following inoculation, mice were immunized with 100 μg of conjugated peptide in 100 μl of PBS emulsified with 100 μl of Freund's complete adjuvant. On the 14 th day, mice were immunized with 100 μg of peptide in 100 μl of PBS emulsified with 100 μl of Freund's incomplete adjuvant. Example 2 [0085] Newly diagnosed GBM preferably undergo at least a 95% resection of the T1-gadolinium enhancing component of the tumor. Prior to vaccination all patients preferably receive at least standard of care external beam radiation. [0086] Vaccine administered directly to patients by treating autologous dendritic cells (DCs) ex vivo with vaccine and then reintroducing the vaccinated DCs into the patient. In some embodiments, vaccines is Peptide A:KLH, Peptide V:KLH, or Peptide P:KLH. Vaccine may be loaded onto autologous DCs, which are matured and used for immunization. Patients undergo leukapheresis to obtain peripheral blood mononuclear cells in preparation for DC generation. DCs are pulsed for two hours with 500 μg of vaccine. Patients receive vaccination using autologous vaccinated DCs administered intradermally for examples into the upper thigh, 10 cm below the inguinal ligament, every 2 weeks beginning 2 weeks following completion of radiation therapy. In some embodiments, patients may receive about 3×10 7 DCs per injection. [0087] Vaccine may be administered directly to patients. In some embodiments, vaccines is Peptide A:KLH, Peptide V:KLH, or Peptide P:KLH. Newly diagnosed EGFRvIII-positive GBM patients may be treated with vaccine administered given intradermally in GM-CSF without accompanying DCs. In some embodiments, two weeks after completing standard external beam radiation therapy, patients receive 3 vaccinations at 2 week intervals of 500 μg of vaccine in 0.8 mL of saline with GM-CSF. Subsequent vaccines may be continued monthly. [0088] Vaccine may be administered directly to patients in combination with chemotherapy. In some embodiments, the vaccine is Peptide A:KLH, Peptide V:KLH, or Peptide P:KLH. The vaccine may be given in coordination with concurrent daily temozolomide (TMZ) in monthly cycles after completion of radiation. Prior to receiving the vaccine, patients undergo >95% volumetric tumor resection, along with standard of care radiation therapy with concurrent TMZ. Newly diagnosed EGFRvIII-positive GBM patients may be treated with vaccine given intradermally in GM-CSF. Vaccine may be administered in a 500 μg dose with GM-CSF near the inguinal region in the upper thigh, on alternating sides. Patients receive TMZ at a dose of 200 mg/m 2 for 5 days of a 28 day cycle or at a dose of 100 mg/m 2 for 21 days of a 28 day cycle. In some embodiments, patients are vaccinated on day 21 of each cycle until progression. first three vaccines may be given biweekly, followed by monthly injections.
Peptides and vaccine compositions comprising peptides based upon EGFRvIII and lacking a glycine at the splice junction are disclosed. The vaccines can induce immune responses against EGFRvIII. Methods of inhibiting formation or growth of EGFvIII tumors, methods of inducing regression of EGFvIII tumors, methods of immunizing against EGFvIII tumors and methods of treating a subjects who have EGFvIII tumors are disclosed.
0
BACKGROUND OF THE INVENTION This invention relates to telephones and, more particularly, to telephone handsets. Telephone construction, operation, and design have changed dramatically since the invention of the telephone by Alexander Graham Bell in U.S. Pat. No. 174,465. Early telephones were cumbersome, crank operated and utilized a separate earpiece connected by a cord to stationary telephone box. The telephone box was mounted on a wall and had a speaker cone providing a mouthpiece. In the 1950s, black bulky telephones were in use with a stationary base on which was mounted a rotatable dial. A movable handset with an earpiece and mouthpiece was connected by a cord to the stationary base. In the 1980s, lighter weight white and colored handsets were developed with pushbuttons between the earpiece and mouthpiece or with pushbuttons on the base. Pushbutton telephones have generally replaced rotary telephones. Pay telephones or telephone pay station included several slots for the deposit of coins of varying denominations. A typical arrangement allowed the deposit of nickels, dimes and quarters so that payment of various amounts could be utilized in connection with the pay station. This arrangement was first used with manual telephones in which the initial deposit of a single coin would signal the operator that a call was to be placed. Additional coins were added for payment of calls to long distance locations. Internal arrangements of gongs transmitted various sounds back to the operator and gave the operator an indication of proper coin deposit. Eventually, telephone pay stations became dial operated, and an operator would normally not be required in order to place local calls. Various arrangements for actuating the equipment and for accepting and returning coins were developed, including electronic totalizers that were able to count and accurately register the number and denomination of coins deposited. Such totalizers also facilitated the development and utilization of single slot pay stations in which a single slot accepted coins of various denominations. Some coin operated telephones and public telephones were developed with a slot or card swipe to receive a telephone identification credit card, or other card with a magnetic strip to enable the user to make calls without the need for cash/coins, by charging the telephone call to the user's account. Telephones that accept credit cards represent a much more recent development that has found widespread use. Pay telephones that accept credit cards are sometimes found in airports, railroad stations, etc., and have been well received by travelers. Recent development and adaptation of the pay station have permitted use in commercial aircraft. Credit card-accepting pay stations have been incorporated into commercial aircraft where, by means of radio-telephone links, telephone service can be made by the user from the commercial aircraft to ground-based telephone equipment. Aircraft telephones themselves have typically been installed on bulkheads located adjacent to flight-attendant stations. This arrangement requires the user to leave the passenger seat to go to the location of the on board pay station to initiate the call. If the pay station is equipped with a wireless telephone unit, the flight attendant often becomes involved in providing the user with the hand-held telephone. Wireless aircraft telephones have been provided with a credit card and reader. In this type of system, the user has to walk to the phone station, insert and leave the credit card in the handset mount to release the handset, then carry the handset back to the passengers seat, and after use, replace the handset and retrieve the credit card. However, with this type of system the passenger cannot obtain the handset during turbulence or at other times when passengers are required to remain in their seats. Furthermore, it is inconvenient to obtain a handset during the time meals are being served and in particular when ones seat is not located on the aisle. Such arrangements fail to afford the convenience and safety, an aircraft passenger might desire in connection with the placement of a call. In the 1980s, personal computers (PCs) were mass produced for businessmen, word processing personnel, financial analysts, bankers, and other consumers. Such personal computers were generally more compact then their predecessors, had greater memory capabilities, and faster processing times. Lap top computers and other portable computers were also produced. Computers can be hooked up with data bases and other computers at distant or remote locations via a modem. Over the years a variety of telephone handsets and other telecommunication equipment have been suggested. Typifying these prior art telephone handsets and telecommunication equipment are those shown in U.S. Pat. Nos. 2,557,393; 4,252,992; 4,488,009; 4,587,379; 4,661,659; 4,672,661; 4,727,569; 4,788,420; 4,811,387; U.S. Pat. No. Design 276,723; U.S. Pat. No. Design 280,986; U.S. Pat. No. Design 297,839; U.S. Pat. No. Design 299,136; U.S. Pat. No. Design 299,137; and U.S. Pat. No. Design 301,034. These prior art telephone handsets and telecommunication equipment have met with varying degrees of success. It is, therefore, desirable to provide a telephone handset with improved features which can also control a display screen of a computer terminal. SUMMARY OF THE INVENTION An improved telephone handset is provided which can be used for many purposes, but is particularly useful for travelers in airplanes, trains, ships, and buses to link up with reservation systems, other data base systems, or their office. Advantageously, the novel telephone handset is versatile, comfortable, and efficient. It is also compact, dependable, and effective. To this end, the novel telephone handset has two sets of control keys, key pads, and/or push buttons. One set activates telephone numbers and the other set activates, controls, and/or signals a display screen of a computer or other central processing unit. One set can be on the front and the other set can be on the back of the telephone handset. In the preferred form, the telephone activating set is positioned on the front of the telephone handset between the earpiece and mouthpiece, and the computer control set is located on the back of the telephone handset. The improved telephone handset also has a card-receiving slot, located either on the back or preferably the front of the telephone handset, to receive an identification card or credit card with a magnetic strip thereon. Desirably, the slot has an enlarged inlet opening providing a mouth with diverging lips or at least one flared, slanted inclined side. In the preferred form, the mouth is located in proximity to the top of the telephone handset and is adjacent one of the sidewalls of the handset. The bottom of the telephone handset can have a cord-receiving opening, adjacent the other of said sidewalls to provide a port or socket to receive a plug or connector of a telephone cord. The universal telephone handset can also have a recessed mouthpiece for enhanced acoustical transmission. In the preferred form, the recessed mouthpiece has triangular sides and an inclined ramp which slopes downwardly and away from said earpiece towards the bottom of the telephone handset. A more detailed explanation of the invention is provided in the following description and claims taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a telephone handset in accordance with principles of the present invention; FIG. 2 is a front view of the telephone handset; FIG. 3 is a left side view of the telephone handset; FIG. 4 is a right side view of the telephone handset; FIG. 5 is a top view of the telephone handset; FIG. 6 is a bottom view of the telephone handset; FIG. 7 is a back view of the telephone handset; and FIG. 8 is a perspective view of a telephone handset with pushbuttons in accordance with principles of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A universal telephone and computer control handset 20 (FIGS. 1-7) is provided which is light weight, compact, and user friendly. Advantageously, the flexible handset 20 has excellent market appeal, is convenient, and attractive to businessmen, travelers, and others. The handset 20 has an elongated separable housing 22 which can be molded out of impact-resistant plastic and can comprise two or more separable parts separated by a parting line for access into the interior of the handset. Other materials can be used. The housing 22 of the handset 20 has substantially planar or flat, upright sidewalls 24 and 26 including a left sidewall 24 (FIG. 3) and a right sidewall 26 (FIG. 4). The sidewalls 24 and 26 are parallel and generally rectangular with rounded corners 28 and 29 (FIGS. 2 and 4). The housing 22 of the handset 20 also has upright end walls 30 and 32 as best shown in FIGS. 5-7. The ends walls include a substantially imperforate top wall 30 (FIG. 5) providing the top of the handset and a bottom wall 32 (FIG. 6) providing the bottom of the handset. The ends walls are parallel, substantially planar or flat, and are generally rectangular with rounded corners 34 and 36. The bottom wall 32 (FIG. 6) has a cord-receiving opening 38 in proximity to the left sidewall 24. The cord-receiving opening 38 provides a port or socket to receive a plug 40, adapter, and/or connector 42, such as a swivel style connector sold under the Trademark and brand name UNTANGLER by Telephone Products, Inc., attached to a telephone cord. The housing 22 of the handset 20 has a back rearward wall 44 (FIG. 7) with a back rearwardly facing surface 46 which provides the back of the handset. The back wall and surface extends horizontally between and connects the end walls 30 and 32 to the sidewalls 24 and 26. The back surface 46 has substantially planar or flat peripheral portions 48 and is generally rectangular with rounded corners 50. The back of the handset has an array, set, and series of finger engagable, computer control keys 52 to remotely control, activate, and signal a central process unit such as a computer with a display screen. In the embodiment of FIG. 7, the computer control keys 52 comprise three columns of alpha, rectangular depressible resilient, key pads 54 in the English alphabet. Each of the columns are sequentially and progressively arranged in increasing order of the alphabet from top 30 to bottom 32 with an enter (ENT) control input key 56. The computer control keys 52 can also include arrow cursor keys 58 to move a cursor in the direction of the arrow on the display screen of a computer. For ease of use of the computer control keys 52, the handset 20 can be turned sideways and laterally 90 degrees or to some other desired position. Key pads using numbers and upper and lower case letters can also be used. The interior facing portions of the key pads 54 are electrically connected to a computer actuated electrical system within the interior of the handset and/or having switches, wires, and/or a circuit board or computer chip, etc. While the illustrated computer control keys are preferred for best results, other arrangements, orientation, pattern, number, shapes, or location of the computer control keys can be used, if desired, and foreign language letters and/or numbers can be used in other countries, if desired. The housing 22 of the handset 20 has a front wall or front 60 (FIG. 2) with a front forwardly facing surface 62 which provides the front of the handset. The front wall and surface extends between and connects the end walls 30 and 32 to the sidewalls 24 and 26. As shown in FIGS. 3 and 4, the front surface 62 has substantially planar or flat portions 64 which are positioned substantially parallel to the back portion 48 of the back 46 of the handset 20. The front surface 62 is generally rectangular as viewed from the front with rounded corners 66. The front wall 60 (FIGS. 1 and 2) of the handset 20 has an earpiece 70 adjacent the top 30 of the handset, a mouthpiece 72 in proximity to the bottom 32 of the handset, and an intermediate control section 74 positioned between the earpiece 70 and the mouthpiece 72. The front wall 60 has an elongated card-receiving slot 76 or swipe to receive the lower portions of an identification card or credit card with a magnetic strip thereon. The earpiece can include a speaker which is connected to a telephone receiving system comprising wires, switches, etc. within the interior of the handset to receive telephone signals from other telephones and unscrambles and converts those signals to recognizable audible tones for the listener's ear. In the embodiment of FIGS. 1 and 2, the earpiece comprises a raised earpiece 70 which extends forwardly of the planar front portion 64 of the front wall 60. The raised earpiece 70 has a substantially rectangular periphery 80 as viewed from the front with rounded corners 82. The raised earpiece 70 has a substantially planar or flat sloping portion or section 84 which extends in a direction upwardly and away from the mouthpiece 72 at an angle of inclination ranging from about 15 to 75 degrees. Positioned on the sloping portion 72, surrounded by the periphery 80, is a concave circular earpiece portion or section 86 with a series of apertures 88 which provides earholes. As shown in FIG. 5, the earpiece 70 can have an inverted U-shaped top portion or section 90 which is positioned flush and in coplanar relationship to the top 30. The top portion 90 can have rounded corners 92. The mouthpiece can include a microphone which is connected to a telephone transmitting system comprising wires, switches, etc. within the interior of the handset which scrambles and converts the user's voice (words) into electrical impulses or signals and transmits those telephone signals to the receiving telephone via telecommunication equipment. In the embodiment of FIGS. 1 and 2, the mouthpiece comprises a recessed mouthpiece 72 with triangular upright sides 94 and 96. An inclined ramped portion or section provides a lower front-facing ramp 98 which extends between and connects the triangular sides 94 and 96 of the mouthpiece 72. The ramp 98 slopes downwardly in a direction away from the earpiece 70 and towards the bottom 32 of the handset 20 at an angle of inclination ranging from about 15 to 75 degrees. The lower portion of the ramp 98 has three inclined slits 100 which provide mouthpiece holes. More or less, or different shaped mouthpiece holes can also be used. The ramp 98 and triangular sides 94 and 96 of the mouthpiece 72 cooperate with each other to define a recessed opening and chamber which can enhance acoustical transmission of the user's voice and lessen outside noise. The intermediate control section 74 (FIGS. 1 and 2) of the front wall 60 of the handset 20 has a set, array, or series of finger engagable, telephone activating control keys 102 to enable the user to send (dial) and transmit the desired telephone number. In the embodiment of FIGS. 1 and 2, the manually engagable control keys comprises resilient depressible, alpha numeric, rectangular key pads 104. The interior facing portions of the key pads 104 are electrically connected to a telephone transmission system comprising switches, wires, etc. within the interior of the handset. While the illustrated telephone control keys are preferred, other arrangements, orientation, pattern, number, shapes, or location of the telephone control keys can be used, if desired, and foreign language letters and/or numbers can be used in other countries, if desired. Pushbuttons can be used in lieu of key pads for the telephone control keys and/or the computer control keys. The handset 120 of FIG. 8 is structurally and functionally similar to the handset 20 of FIGS. 1-5, except that raised rectangular pushbuttons 106 are used instead of key pads. In some circumstances, it may be desirably to use cylindrical, curved, rounded, or concave pushbuttons, or pushbuttons of other configurations. The card-receiving slot 76 (FIGS. 1 and 2) is substantially parallel and adjacent the right sidewall 26. As viewed from the front wall 60, the slot extends vertically through the top 30 and bottom 32 of the handset 20. To facilitate entry of the card, the slot 76 has an enlarged card-receiving inlet opening 110 providing a mouth. The specially shaped mouth 110 of the illustrated embodiment also provides a latch receiving-opening to receive and engage a locking latch, such as connected to a handset housing or wall. In the illustrated embodiment, the mouth 110 has a substantially triangular lower section 112 and a rectangular upper section 114. The mouth 110 has a straight outer right side 116 extending along the upper and lower sections 112 and 114. The outer right side 116 communicates with the slot 76 and is positioned contiguous with the slot 76 along the right sidewall 26. The upper rectangular section 114 has an upright inner left side 118 positioned substantially parallel to the right outer side 116. The lower section 112 has a tapered angled left camming side 122 providing a cam or inclined camming surface which diverges and slopes inwardly and upwardly in a direction towards the top 30 of the handset 20 at an angle of inclination ranging from about 15 to 45 degrees relative to the elongated vertical slot 76 as viewed from the front wall 60. The angled side 122 extends between and connects the inner left side 118 to the elongated left wall section 124 of the slot 76. The elongated left wall section 124 is positioned across and parallel to the elongated right wall section 126 of the slot 76. The telephone handset 20 comprises a credit card station with a card receiving slot structure 76 having an open outer edge 118 which is accessible for receiving a stripe containing portion of a credit card for manually controllable movement of the magnetic stripe along a path defined in the slot structure 76 while the card is still manually gripped by the user. The slot structure 76 includes a pair of spaced apart opposite sidewalls sections 124 and 126. The slot 76 provides a longitudinal path of movement for the credit card. The slot structure 76 can also include a guide provided between the sidewall sections 124 and 126 intermediate the ends. Sensors 138 of an internal magnetic card reader can be positioned in front of the window 128 within the handset 20 for reading the characters on the magnetic stripe of a credit card to enable the calls to be charged when particular characters are present on a credit card and ready by the sensors 138 of the reader. The slot structure 76 includes an credit card receiving end 110 in which the tapered upper portion 122 of the left sidewall section 124 is inclined and bent away from the right sidewall section 126 to provide a notch to facilitate insertion of the card until the longitudinal edge of the card directly engages the sensor 138 of the card reader. The slot structure 76 can includes an outwardly sloping surface adjacent an opposite, exit end portion of the slot structure which directs the card outwardly of the open edge of the slot structure 76 upon passage of the card beyond the card reader sensor 138 to facilitate withdrawal of the card from the slot 76 by the user. In the illustrative embodiment, the telephone handset 20 includes an elongated, generally vertically extending slot structure 76 on the right hand side of the front wall 60. The slot structure 76 has an outline or profile which matches the right sidewall 26 of the telephone handset 20. The slot structure 76 is formed by a pair of elongated opposite, spaced apart sidewall sections 124 and 126 made of nonmagnetic material such as impact and resistant plastic or stainless steel sheet material. The facing inside surfaces of the left hand and right hand slot structure sidewall sections can be maintained in spaced apart parallel relation by an intermediate guide member also formed of impact-resistant plastic or stainless steel. The middle or intermediate portion of the slot structure of the left hand sidewall section 124 is formed with a rectangular shaped window 128 so that one or more sensors or sensing elements 138 of a magnetic card reader can read the magnetic characters on the surface of a credit card passing by in front of the window 128 while guided along a prescribed path by the guide rib of the guide slot. The card reader can be housed in the interior of the handset. At the upper end of the slot structure 76, the left hand sidewall section is angled along surface 122 to diverge outwardly and away from the opposite right hand sidewall section 126 so as to provide a wider open portion 110 at the upper end of the slot structure 76 to facilitate manual insertion of a card into the slot structure 76. In order to use a credit card, a telephone user grasps the credit card and inserts the lower portion of the credit card containing the magnetic stripe into the slot 76 so as to face the window 128 and sensor 138 of the magnetic card reader, while still gripping the upper portion of the credit card. The user continues to grip the credit card and moves their hand downwardly, all the time pressing the longitudinal edge against an upper guide surface of the guide. This engagement insures that the magnetic stripe of the credit card will move along a generally vertical path, so as to align the magnetic strip to pass directly in front of the card reader window 128 so that the card reader may sequentially read and record the magnetic information contained on the card. When the lower edge of the card first passes the upper edge of the window 128, the card reading process begins to take place and continues until the upper or trailing end of the card moves past the lower edge of the window 128. After activating the handset with a credit card, the user can operate the telephone and/or computer keys, as desired. The user can also contact the telephone operator by dialing zero (0), or can operate the telphone or use the computer control keys via preauthorized access codes. Among the many advantages of the novel telephone handset are: 1. Outstanding appeal to businessmen and travelers. 2. Superior performance. 3. Versatile. 4. Reliable. 5. Convenient. 6. Easy to use. 7. Simple to operate. 8. Compact. 9. Economical 10. Safe 11. Efficient 12. Effective Although embodiments of the invention has been shown and described, it is to be understood that various modifications and substitutions, as well as rearrangements of parts, can be made by those skilled in the art without departing from the novel spirit and scope of this invention.
A convenient versatile telephone handset has one set of telephone activating keys and another set of computer control keys. The special telephone handset can also have a card-receiving slot and a recessed mouthpiece. Advantageously, the flexible telephone handset is particularly useful for business travelers in airplanes, trains, and buses to link up to reservation systems and other data bases.
7
TECHNICAL FIELD This invention relates to the excavation of ditches or trenches and to their reinforcement by piles or other wall forming means. BACKGROUND ART In most trenching operations in soft soil, the cross-section of the excavation area turns out to be of generally trapezoidal shape. Although the hoe or similar excavation means will initially remove only a rectangular section of soil, almost invariably the upper edges of the trench so dug will then cave in and leave the trapezoidal form mentioned above. A wider horizontal section of soil is therefore customarily removed from the top than is required by the dimensions of the bottom of the trench. The same phenomenon necessitates the use of substantial areas outside and alongside the trench for positioning pile driving means in order to reinforce the walls of the excavated ditch. Because such piling is usually driven in perpendicular to the bottom of the trench, the top section of each pile is freestanding and not supported by the surrounding soil. It must therefore be driven in a substantial distance beyond the bottom of the trench in order to assure the required structural rigidity for the sidewalls thus formed. There are many situations, however, where the room for operating trenching and piling equipment is severely restricted, both horizontally and, possibly, even vertically, be it because of problems of access and right-of-way or because of geological conditions and where control of grade and line is important. In such circumstances the desirability of digging and reinforcing trenches with truly vertical sidewalls and with a minimum of lateral surface access requirements has long been recognized by the industry. See, for example, U.S. Pat. No. 4,279,548, entitled "Hydraulic Propulsion Unit", issued July 21, 1981, to Raymond W. Ramey. It is the object of the present invention to satisfy this long felt need and the need for speed of excavation and uniformity of trench and operation with the help of a hydraulic, self-advancing excavation unit which requires the removal of, and access to, no more soil than is actually defined by the dimension of the trench while using a propulsion system anchored in front of the unit to produce a trenching machine quality, uniform trench in conjunction with standard trenching tools, such as a back hoe. DISCLOSURE OF INVENTION The present invention provides a trenching shield device for use in preparing for the excavation of ditches and for subsequently reinforcing the sidewalls of the ditches. The trenching shield is used in conjunction with a back hoe or similar excavation mechanism and in conjunction with a pile driving apparatus for inserting piles along the walls of the ditch. The trenching device of the present invention comprises an excavation box having metal sidewalls connected by spacer plates with cutting means mounted on the front edges of these sidewalls, and propulsion means mounted on the box for advancing the excavation box in conjunction with anchoring means in front of the box. The anchoring means, when implanted in the earth in front of the box, provides the support for propelling the excavation box forward into the facing earth through the expansion of the hydraulic propulsion means combined with the action of the cutting means disposed along the front edges of the sidewalls. Initially, however, slightly more than the thickness of the sidewalls is cut by the cutting means as the box advances. The bulk of the soil between the sidewalls is then scooped up by customary digging means positioned outside or in front of the submerged excavation box. Pilings are driven in as the box advances right behind; i.e.: inside of, the rear portion of the sidewalls of the excavation box. Advancing the box is facilitated through a set of beams along which alternatingly the propulsion mechanism can slide relative to the box and remain fixed relative to the box. Accordingly, the propulsion means can force the box to slide forward, pushed by expanding the propulsion means, with respect to the anchoring means and the anchoring means can be forced forward with respect to the stationary excavation box as part of contraction cycle of the propulsion means. This invention is described to some extent in the "Abstract of the Invention" which is attached hereto and incorporated herewith by reference. BRIEF DESCRIPTION OF THE DRAWINGS For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like parts are given like reference numerals, and wherein: FIG. 1 is a perspective view of the preferred embodiment of the self propelled trench shield of the present invention; FIG. 2 is a side cross-sectional view of the preferred embodiment of the trench shield of the present invention taken along section line 2--2 of FIG. 1; FIG. 3 is a cross-sectional view of the preferred embodiment of one of the anchor and propulsion mechansim of the preferred embodiment of the trench shield of the present invention; FIG. 4 is a cross-sectional view of the anchor and propulsion mechanism taken along section line 4--4 of FIG. 3; FIG. 5 is a cross-sectional view of the anchor and propulsion mechanism taken along section line 5--5 of FIG. 3; FIG. 6 is a cross-sectional view of the anchor and propulsion mechanism taken along section line 6--6 of FIG. 3; FIG. 7 is a cross-sectional view of the anchor and propulsion mechansim taken along section line 7--7 of FIG. 3; FIG. 8 is a cross-sectional view of the anchor and propulsion mechanism taken along section line 8--8 of FIG. 3; FIG. 9 is a cross-sectional view olf the anchor and propulsion mechanism taken along section line 9--9 of FIG. 3; FIG. 10 is a cross-sectional view of the anchor and propulsion mechanism taken along section line 10--10 of FIG. 3; FIG. 11 is a diagrammatic, partial, side cross-sectional view of the anchor and propulsion mechanism showing a portion of the preferred embodiment of the propulsion mechanism; and FIG. 12 is a diagrammatic, partial, side cross-sectional view of the anchor and propulsion mechanism showing a portion of another embodiment of the propulsion mechanism. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIGS. 1 and 2, there is shown the self propelled trench shield of the present invention. The shield can be seen to comprise three main components: an excavation box 2, propulsion means 4, and anchor means 6. The excavation box 2 includes side plates 10, 12 separated by front and rear spacer plates 14, 16. The side plates 10, 12 and front and rear spacer plates 14, 16 divide the excavation box 2 into three main sections: a front section 7, within which cutting or excavation means are either located or applied, a mid section 8 wherein the control means, power plants and majority of the propulsion means 4 is located, and a rear section 9 within which piling reinforcement of the excavated trench takes place. Accordingly, each of plates 10, 12 has three sections, a front section 18, and mid section 20, and a rear section 22. Front section 18 has a cross-sectional shape of that of a trapezoid with sides 24, 26, 28, 30. Sides 24 and 26 are parallel to each other, and side 28 is perpendicular to sides 24, 26. Side 30 has a slope, preferably, of 1/2: 1 to minimize sluffing of the dirt encountered by side 30 during the trenching operation; i.e.: to provide the best angle of repose for digging face stability. Accordingly, the front section 7 is bounded by front spacer plate 14 and front sections 18 of side plates 10, 12. The cantilever front sections 18 provide an unobstructed access for a back hoe (not shown) to perform excavation work. Front sections 18 have a depth designed to penetrate the digging face to prevent lateral caving of the trench and may be approximately eleven feet in depth at the top and four feet in depth at the bottom to permit the entry of the bucket for excavation. An earth digging auger 32 is attached to and runs parallel with each side 30. Each auger 22 has two helical sections 36, 38 connected by an intermediate bearing 40 at one end of each of helical members 36, 38. Auger 32 is attached to side 30 at the lower end of helical section 38 by thrust or carrier bearing 34. The other end of helical section 36 is connected to hydraulic motor/bearing 42 attached to side 26 by a plate 41 through welding or other suitable means. Hydraulic motor/bearing 42 is driven by a hydraulic power source (not shown). The helical teeth of sections 36, 38 of the auger 32 are oversized to be several inches wider than the wall thickness of front section 18, such as thirteen inches in size for a wall thickness of twelve inches, so as to cut a way for the wall. This permits the front section 18 to be thrust into the digging face. The mid section 8 is bounded by front plate 14, rear plate 16, and mid sections 20 of side plates 10, 12. Referring to FIGS. 1, 2, 11, 12, plate 14 includes four openings, such as opening 19 of FIGS. 11, 12, in which are mounted bearings 21, 23, 25, and 27. The openings, such as opening 19 in FIGS. 11, 12, are aligned with openings, such as opening 29 in FIGS. 11, 12, in inwardly facing lips or faces, such as lip or face 31 in FIGS. 11, 12. The lips are mounted by welding or bending or other suitable means on sides 30, such as being a face of a channel section. A second set of bearings 33, 35, 37, 39 are mounted behind each of these second openings, such as opening 29 in FIGS. 11, 12, by welding to two plates welded to the lips, such as plates 43, 45 in FIGS. 11, 12. The control portion (not shown) for the anchor means 6, the propulsion means 4, the motor/bearings 42 and other hydraulic mechanisms are located in mid section 8. Also located in mid section 8 are the hydraulic pumps and diesel motor that drives these mechanisms. The rear section 8 is bounded by rear spacer plate 16 and rear sections 22 of side plates 10, 12. Sections 22 of plates 10, 12 are adapted to receive along themselves flat piles customarily used in the art which are driven into the soil on the inner sides of sections 22 by any of the usual means known in the art, such as pile driving or vibrating, while the excavation box 2 of the present invention advances. It is, therefore, not necessary to interrupt the excavation process and to remove the excavation box 2 in order to insert piles along the walls of the trench. In the preferred embodiment, plates 10, 12, 14, 16 are constructed of steel plate of sufficient thickness to withstand the pressure from the adjacent earth and ocassional battering from the backhoe and pile driving mechanisms. The anchor means 6 includes four anchor helixes 52, 54, 56, 58 extending forward of section 7. These helixes are commercially available, such as from Anchoring International, for drilling laterally into dirt. Each helix 52, 54, 56, 58 has a rear bearing surface which prevents easy extraction by pulling out of the dirt. The propulsion means 4 includes drive sections 60, 62, 64, 66 for anchor helixes 52, 54, 56, 58, and shaft sections or kellys 68, 70, 72, 74 attached thereto, respectively, and to anchor helixes 52, 54, 56, 58, respectively. A portion of each kelly 68, 70, 72, 74 extends beyond section 7 and connects to helixes 52, 54, 56, 58, respectively, by bolts, such as bolts 76, 78 for helix 54 and kelly 70 as shown in FIG. 3. Referring to FIGS. 3, 11, 12, a typical anchor helix 54, drive section 62 and kelly 70 are shown. FIG. 3 best illustrates the anchor helix 54, drive section 62 and kelly 70 required for the continuous mode of operation of the propulsion means 4 of the present invention. In the preferred embodiment of the present invention, the anchor helixes, drive sections and kellys are symmetrical in structure and function. Therefore, only one such shall be described in detail, it being understood that, unless expressly noted otherwise, there exist a corresponding counterpart to every part referred to in the following description. As shown in FIGS. 3, 11, 12, kelly 70 extends from anchor helix 54 through drive section 62 and into the interior of mid section 8. Kelly 70 may be rotated, preferably, by an hydraulic motor 46 (FIG. 11) mounted by plates 47, 49 to plate 14. Kelly 70 would be coaxial with the interior 51 axis of the motor 46 and would be rotated about its axis. Motor 46 could be of a hollow core type as manufactured by Rineer Hydraulics, Inc. It should be noted that this method is preferable because all motors could be initially mounted as an integral part of the drive section 62 and all helixes could be rotated simultaneously. Alternatively, as shown in FIG. 12, a motor 53 may be mounted behind drive section 62, such as by a crane (not shown) and attached to the end 55 (FIG. 12) of the kelly 70. In this alternate embodiment, the kelly 70 could have the motor 53 mounted on it selectively, have it removed, and have the motor 53 used with other helixes. Motor 53 could also be of the same type as motor 42. It should be noted that the motors 46, 53 are selected to yield low speed rotation under normal circumstances. The remainder of drive sections 60, 62, 64, 66 required for the continuous mode of operation of the present invention are best illustrated in FIG. 3 by drive section 62. Drive section 62 includes support structure 84 and propulsion structure 86 which support kelly 70 and anchor helix 54. Support structure 84 includes spaced apart, parallel mounted wide flange beams 90, 92. Beams 90, 92 include outer flanges 94, 96. Beams 90, 92 are mounted by attaching flanges 94, 96, respectively, flushly against section 20 by welding or other suitable means. Oppositely disposed U-structures 98, 100 are mounted on the webs 102, 104, respectively, of beams 90, 92, respectively. U-structures 98, 100 include sides 99, 101, respectively, and bottoms 103, 105, respectively. Bottoms 103, 105 are connected by welding or other means to webs 102, 104. Sides 99, 101 are connected by welding or other means to flanges 95, 97, respectively. Structures 98, 100 open to face each other with oppositely disposed tips 107, 109, respectively, of sides 99, 101. The interior of each U-structure 98, 100 houses teeth 106, 108 which are saw tooth in shape, formed by cutting or other suitable means, and attached to the U-shaped structures 98, 100, respectively, by welding or other suitable means. The propulsion structure 86 includes rachet assembly 110 at its leading edge mounted about a cylinder 112. Rachet assembly 110 includes dogs 114, 116 connected near their outer ends to springs 118, 120, respectively. The other end of springs 118, 120 are connected to cylinder 112. These connections may be by welding or other suitable means. The inner end of dogs 114, 116 have passageways 115, 117 formed laterally therethrough by drilling or other means. Pins 122, 124 are rotatably received in passageways 115, 117, respectively. Pins 122, 124 are also rotatably mounted on ears 126, 128, respectively, which are welded to cylinder 112. Ears 126, 128 also held together by back plate 130 which has a hollow central opening 131 to fit over cylinder 112. Back plate 130 is welded to the inner end of ears 126, 128. The springs 118, 120 are designed to force dogs 114, 116, respectively, outwardly away from cylinder 112. Plate 130 is also connected to a hollow piston 132 of a hollow core jack 129, such as that obtainable from Enerpac, a division of Applied Power, Inc. Co. Piston 132 includes hollow cylindrical center 135 bounded by the cylindrical inner wall 136 of piston 132 and is reciprocally mounted about receiving cylinder 133 in center 135. Piston 132 is also reciprocally mounted in hydraulic cylinder 134. Piston 132 further has a enlarged, hollow flange 137 having outer side 139 facing inwardly facing side 141 of cylinder 133 and inner side 143 facing outwardly facing side 145 of cylinder 133. Jack 129 is double acting and is connected (by means not shown) to a suitable source of driving media, such as a hydraulic fluid pump. Cylinder 134 includes retracting arms 139, 140 at its outwardly facing end. Arms 138, 140 are disposed on opposite ends of cylinder 134 and are disposed in the same longitudinal orientation as dogs 114, 116, respectively. A split strap mechanism 142 circumferentially surrounds cylinder 134 near its inwardly facing end 144. Strap 142 is sized to slip over cylinder 134. Strap 142 includes strap sections 146, 148, having upper flanges 150, 152, respectively. Flanges 150, 152 have holes 151, 153, respectively laterally therethrough and are pinned by bolt 154 extending through holes 151, 153. Ears 158, 160 extend longitudinally from the lower portion of straps 146, 148, respectively. Ears 158, 160 have lateral openings 162, 164, respectively, through their lower ends. Metal rollers 166, 168 are rotatably mounted in and have their outer ends extend through openings 162, 164, respectively. Rollers 166, 168 are rotatably connected at their inner ends to liner/spacer 170 which extends into the upper space of U-structure 100. Cylinder 133 is coaxial with and of larger diameter than cylinder 112. The bottom 171 of a container ring 172 is mounted, by welding or other suitable means, to end 144 of cylinder 134. Container ring 172 includes outer face opening 173 which is circular in shape, coaxial with cylinder 133, and of approximately the same diameter as the inner diameter of cylinder 133. Opening 173 is formed by cutting or other suitable means. Ring 172 further includes cylindrical sidewall 175 and an annular opening 174 at its inwardly facing end bounded by circular flange 176. Flange 176, base 171, and sides 175 form a cylindrical space 177 therebetween . The enlarged section 179 of a swivel 178 is mounted in space 177. Swivel 178 further includes a narrow section 180 extending longitudinally inward from enlarged section 179 through opening 174. Enlarged section 179 is rotatably mounted in chamber 177 and, when rotating, normally has its outwardly facing surface 181 abutting the inwardly facing surface of base 173 with a grease coating (not shown) therebetween. Swivel 178 further has hollow center 182 coaxial with cylinder 133 surrounding kelly 70. Section 180 and kelly 70 have juxtaposed openings 184, 186, respectively, therethrough which are coaxial. Pins 188 extend through such openings and connect cylindrical section 180 to kelly 70. Accordingly, kelly 70 is pinned to the helix 54 with bolts 76, 78 and extends through cylinder 112, cylinder 133, opening 173, opening 182 and past the end of section 178 and is also pinned to section 180 with pins 188. In operation, a pit is first excavated to line and grade to begin the trench. The trench shield box 2 is then placed and oriented in the pit to line and grade. Piston 132 is then forced by hydraulic fluid flowing through openings in the outer ends (not shown) between faces 139, 141 in cylinder 134 until flange face 143 abuts face 145. As piston flange face 143 approaches cylinder face 145, dogs 114, 116 come into sliding contact with retraction arms 138, 140, respectively, which force dogs 114, 116 to rotate about pins 122, 124, respectively, toward cylinder 112. After dogs 114, 116 are retracted, section 62 is forced forward and kelly 70 is rotated slowly by motor 46 or motor 53. Anchor helix 54 is thereby rotated and driven into the earth in front of the box 2. After the anchor helix 54 is augered into the digging face of the earth, hydraulic fluid is forced into the cylinder (by means not shown) between faces 143, 145, thereby forcing flange 137 away from face 145. Dogs 114, 116 are then forced from under arms 138, 140 and are extended by springs 118, 120, respectively, so that they engage teeth 106, 108, respectively. Further force applied between faces 143, 145 push the entire trencher box 2 forward along kelly 70 towards the digging face of the earth in which helix 54 is embedded. Motors 42 are activated so that the auger members 36, 38 will bite into the digging surface of the earth. At the end of each stroke of piston 132, it is retracted by hydraulic fluid forced in between faces 139, 141, thereby forcing flange face 143 towards cylinder face 145. Dogs 114, 116 are thereby pulled inwardly and ride up teeth 106 108, and fall into the next tooth valley. After the dogs 114, 116 have fallen into the next valleys, the hydraulic pressure is reversed, forcing flange 137 away from surface 145 to further cause the trencher box 2 to move forward. After solid contact has been made between the earth and the forward edges of the trencher, excavating of the space 7 can begin by a backhoe or other similar mechanism with augers graders 36, 38 aiding in the operation. As the backhoe completes excavation of a portion of the dirt, the piston 132 is again activated to force the trencher box 2 forward closer to the anchor helix 54. After several of these operations, either the anchor helix 54 will no longer have sufficient dirt to support it or the dogs 114, 116 will have reached the end of the teeth 106, 108. In either case, the dogs 114, 116 are again pulled under the retracting arms 138 and 140, respectively, and the drilling operation is commenced again. As the trencher box 2 moves forward, shoring by either steel sheet piling or wood is installed in the trailing end 9 against the sides 22. Therefore, as the trencher box 2 moves forward beyond the shoring, the shoring is in place to prevent collapse of the earth in the trench. Each of the hydraulic jacks 129 is, for example, of the 150 on capacity which may be obtained from commercial sources such as Enerpac, a division of Applied Power, Inc. In addition, the hydraulic power may be supplied by any suitable source, such as a 3208 Caterpillar engine driving three hydraulic pumps. The power module is usually attached to the top of the mid section 8 located so as to be above the trench to provide good operator visibility and to keep exhaust fumes out of the trench. An operator station complete with valve control and pressure gauges would be provided on the power module. Although the system described in detail above is most satisfactory and preferred, many variations in structure and methods are possible. Examples of these possible changes and variations have been given above in the specification. Because of many varying and different embodiments may be made within the scope of the inventive concept herein taught and because modifications may be made in accordance with the descriptive requirements of the law, it should be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.
An apparatus and a method for excavating and pile reinforcing trenches is disclosed. A box-like central structure serves as a frame within which excavation by customary means, e.g., externally positioned back hoes, takes place. The outside walls of said central structure form temporary trench walls supporting the surrounding dirt. The inside walls of said central structure form a rear section, behind which flat piling is driven in before the entire unit advances. Advancement is carried out by means of longitudinal anchoring to the earth in the direction of travel of the apparatus and a longitudinal propulsion mechanism riding on the box frame and alternatively drilling and pushing periodically. In addition, end aligned shafts with cutting members are disposed within the front edges of the box frame walls to facilitate tunneling forward during the propulsion cycle.
4
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application is a National Stage of PCT/CH07/000101 filed Feb. 28, 2007 FIELD OF THE INVENTION [0002] The present invention provides template-fixed β-hairpin peptidomimetics which are having CXCR4 antagonizing activity and are embraced by the general disclosure of, but not specifically disclosed in WO2004/096840 A1. SUMMARY OF THE INVENTION [0003] The β-hairpin peptidomimetics of the invention are Cyclo(-Tyr-His-X-Cys-Ser-Ala- D Pro-Dab-Arg-Tyr-Cys-Tyr-Gln-Lys- D Pro-Pro), disulfide bond between Cys4 and Cys11, and pharmaceutically acceptable salts thereof, with X being Ala or Tyr. BRIEF DESCRIPTION OF THE DRAWINGS [0004] FIG. 1 . Increase in Colony Forming Units per ml of blood (CFU-GM) over time for both the compound of Example 1 (5 mg) and the reference compound AMD3100. [0005] FIG. 2 . Increase in Colony Forming Units per ml of blood (CFU-GM) over time for both the compound of Example 2 and the reference compound AMD3100. [0006] FIG. 3 . Average number of CD34(+) cells per μL of blood over time for compound of Example 1 DETAILED DESCRIPTION OF THE INVENTION [0007] In accordance with the invention, the aforesaid β-hairpin mimetics and pharmaceutically acceptable salts thereof can be prepared by a process which comprises [0000] (a) coupling an appropriately functionalized solid support with an appropriately N-protected derivative of Pro; (b) removing the N-protecting group from the product obtained in step (a); (c) coupling the product thus obtained with an appropriately N-protected derivative of D Pro; (d) removing the N-protecting group from the product thus obtained; (e) coupling the product thus obtained with an appropriately N-protected derivative of the amino acid which in the desired end-product is in position 14, i.e. Lys, the amino group present in its side-chain being likewise appropriately protected; (f) removing the N-protecting group from the product thus obtained; (g) effecting steps substantially corresponding to steps (e) and (f) using appropriately N-protected derivatives of the amino acids which in the desired end-product are in positions 13 to 1, i.e. Gln, Tyr, Cys, Tyr, Arg, Dab, D Pro, Ala, Ser, Cys, Ala or Tyr, His and Tyr, any functional group which may be present in said N-protected amino acid derivatives being likewise appropriately protected; (h) forming the disulfide β-strand linkage between the side-chains of the Cys residues in positions 4 and 11; (i) detaching the product thus obtained from the solid support; (j) cyclizing the product cleaved from the solid support; (k) removing any protecting groups present on functional groups of any members of the chain of amino acid residues; and (l) if desired, converting the product thus obtained into a pharmaceutically acceptable salt or converting a pharmaceutically acceptable, or unacceptable, salt thus obtained into the corresponding free compound or into a different, pharmaceutically acceptable, salt. [0008] The steps of the aforesaid process can be carried out by methods which are well known to any person adequately skilled in peptide chemistry. [0009] The β-hairpin peptidomimetics of the invention can be used in a wide range of applications for preventing HIV infections in healthy individuals or for slowing and halting viral progression in infected patients; or where cancer is mediated or resulting from CXCR4 receptor activity; or where immunological diseases are mediated or resulting from CXCR4 receptor activity; or for treating immuno suppression; or for treating inflammation, or, in particular, for stem cell mobilisation of peripheral blood stem cells and/or mesenchymal stem cell (MSC) and/or other stem cells which retention depend on the CXCR4-receptor. [0010] The β-hairpin peptidomimetics of the invention may be administered per se or may be applied as an appropriate formulation together with carriers, diluents or excipients well known in the art. [0011] In particular, the β-hairpin peptidomimetics of the invention can be used as a treatment to increase hematopoetic stem cell (HSC) release from the bone marrow to be used in allogenic or autologous transplant. [0012] The acute treatment with infused HSC is widely used to restore immune functions in patients who have received myeloablative therapy during the treatment of malignancies such as multiple myeloma and non-Hodgkin's lymphoma. Patients or donors are treated with the HCS mobilisation agent, such as a compound of the invention, and the cells are subsequently collected from peripheral blood by apharesis. HCS are transplanted back after e.g. chemotherapy treatment into the patient (autologous transplant) or from donor to recipient (allogenic transplant), thus promoting the restoration of immune function (Frühauf et al., Br. J. Haematol. 122, 360-375 (2003)). [0013] Other applications of the HSC treatment include, but are not limited to, therapeutic angiogenesis in case of e.g. heart attack (Shepherd R M et al, Blood 2006 108(12):3662-3667). [0014] The β-hairpin peptidomimetics of the invention may also be used to treat or prevent HIV infections or cancer such as breast cancer, brain cancer, prostate cancer, lung cancer, kidney cancer, neuroblastoma, non-Hodgkin's lymphoma, ovarian cancer, multiple myeloma, chronic lyphomphocytic leukemia, pancreatic cancer, melanoma, angiogenesis and haematopoetic tissues; or inflammatory disorders such as asthma, allergic rhinitis, hypersensitivity lung diseases, hypersensitivity pneumonitis, eosinophilic pneumonias, delayed-type hypersensitivity, interstitial lung disease (ILD), idiopathic pulmonary fibrosis, ILD associated with rheumatoid arthritis, systemic lupus erythematosus, ankylosing spondylitis, peripheral vascular disease, systemic sclerosis, Sjogren's syndrome, von Hippel Lindau disease, systemic anaphylaxis or hypersensitivity responses, drug allergies, rheumatoid arthritis, psoriatic arthritis, Behcet's Syndrome, mucositis, Crohn's disease, multiple sclerosis, myasthenia gravis, juvenile onset diabetes, glomerulonephritis, autoimmune throiditis, graft rejection, including allograft rejection or graft-versus-host disease, inflammatory bowel diseases, inflammatory dermatoses; or to treat immunosuppression, including immunosuppression induced by graft/transplantation rejection. [0015] The β-hairpin peptidomimetics of the invention can be administered singly, as mixtures of more than one β-hairpin peptidomimetics, in combination with, as the case may be, other HSC mobilisation agents, or anti-HIV agents, or antimicrobial agents, or anti cancer agents, or anti-inflammatory agents, and/or in combination with other pharmaceutically active agents. [0016] Pharmaceutical compositions comprising β-hairpin peptidomimetics of the invention may be manufactured by means of conventional mixing, dissolving, granulating, coated tablet-making, levigating, emulsifying, encapsulating, entrapping or lyophilizing processes. Pharmaceutical compositions may be formulated in conventional manner using one or more physiologically acceptable carriers, diluents, excipients or auxilliaries which facilitate processing of the active β-hairpin peptidomimetics into preparations which can be used pharmaceutically. Proper formulation depends upon the method of administration chosen. [0017] For topical administration the β-hairpin peptidomimetics of the invention may be formulated as solutions, gels, ointments, creams, suspensions, etc. as are well-known in the art. [0018] Systemic formulations include those designed for administration by injection, e.g. subcutaneous, intravenous, intramuscular, intrathecal or intraperitoneal injection, as well as those designed for transdermal, transmucosal, oral or pulmonary administration. [0019] For injections, the β-hairpin peptidomimetics of the invention may be formulated in adequate solutions, preferably in physiologically compatible buffers such as Hank's solution, Ringer's solution, or physiological saline buffer. The solutions may contain formulatory agents such as suspending, stabilizing and/or dispersing agents. [0020] Alternatively, the β-hairpin peptidomimetics of the invention may be in powder form for combination with a suitable vehicle, e.g., sterile pyrogen-free water, before use. [0021] For transmucosal administration, penetrants appropriate to the barrier to be permeated are used in the formulation as known in the art. [0022] For oral administration, the compounds can be readily formulated by combining the active β-hairpin peptidomimetics of the invention with pharmaceutically acceptable carriers well known in the art. Such carriers enable the β-hairpin peptidomimetics of the invention to be formulated as tablets, pills, dragees, capsules, liquids, gels, syrups, slurries, suspensions etc., for oral ingestion by a patient to be treated. For oral formulations such as, for example, powders, capsules and tablets, suitable excipients include fillers such as sugars, e. g. lactose, sucrose, mannitol and sorbitol; cellulose preparations such as maize starch, wheat starch, rice starch, potato starch, gelatin, gum tragacanth, methyl cellulose, hydroxypropylmethyl cellulose, sodium carboxymethylcellulose; granulating agents; and binding agents. If desired, desintegrating agents may be added, such as cross-linked polyvinylpyrrolidones, agar, or alginic acid or a salt thereof, such as sodium alginate. If desired, solid dosage forms may be sugar-coated or enteric-coated using standard techniques. [0023] For oral liquid preparations such as, for example, suspensions, elixirs and solutions, suitable carriers, excipients or diluents include water, glycols, oils, alcohols, etc. In addition, flavoring agents, preservatives, coloring agents and the like may be added. [0024] For buccal administration, the composition may take the form of tablets, lozenges, etc. formulated as usual. [0025] For administration by inhalation, the β-hairpin peptidomimetics of the invention are conveniently delivered in form of an aeorosol spray from pressurized packs or a nebulizer, with the use of a suitable propellant, e.g. dichlorodifluoromethane, trichlorofluromethane, carbon dioxide or another suitable gas. In the case of a pressurized aerosol the dose unit may be determined by providing a valve to deliver a metered amount. Capsules and cartridges of e.g. gelatin for use in an inhaler or insufflator may be formulated containing a powder mix of the β-hairpin peptidomimetics of the invention and a suitable powder base such as lactose or starch. [0026] The compounds may also be formulated in rectal or vaginal compositions such as suppositories together with appropriate suppository bases such as cocoa butter or other glycerides. [0027] In addition to the formulations described previously, the β-hairpin peptidomimetics of the invention may also be formulated as depot preparations. Such long acting formulations may be administered by implantation (e.g. subcutaneously or intramuscularly) or by intramuscular injection. For the manufacture of such depot preparations the β-hairpin peptidomimetics of the invention may be formulated with suitable polymeric or hydrophobic materials (e.g. as an emulsion in an acceptable oil) or ion exchange resins, or as sparingly soluble salts. [0028] In addition, other pharmaceutical delivery systems may be employed such as liposomes and emulsions well known in the art. Certain organic solvents such as dimethylsulfoxide may also be employed. Additionally, the β-hairpin peptidomimetics of the invention may be delivered using a sustained-release system, such as semipermeable matrices of solid polymers containing the therapeutic agent. Various sustained-release materials have been established and are well known by those skilled in the art. Sustained-release capsules may, depending on their chemical nature, release the compounds for a few weeks up to over 100 days. Depending on the chemical nature and the biological stability of the therapeutic agent, additional strategies for protein stabilization may be employed. [0029] As the β-hairpin pepdidomimetics of the invention contain charged residues, they may be included in any of the above-described formulations as such or as pharmaceutically acceptable salts. Pharmaceutically acceptable salts tend to be more soluble in aqueous and other protic solvents than are the corresponding free forms. Particularly suitable pharmaceutically acceptable salts include salts with, carboxylic, phosphonic, sulfonic and sulfamic acids, for example acetic acid, propionic acid, octanoic acid, decanoic acid, dodecanoic acid, glycolic acid, lactic acid, fumaric acid, succinic acid, adipic acid, pimelic acid, suberic acid, azelaic acid, malic acid, tartaric acid, citric acid, amino acids, such as glutamic acid or aspartic acid, maleic acid, hydroxymaleic acid, methylmaleic acid, cyclohexanecarboxylic acid, adamantanecarboxylic acid, benzoic acid, salicylic acid, 4-aminosalicylic acid, phthalic acid, phenylacetic acid, mandelic acid, cinnamic acid, methane- or ethane-sulfonic acid, 2-hydroxyethanesulfonic acid, ethane-1,2-disulfonic acid, benzenesulfonic acid, 2-naphthalenesulfonic acid, 1,5-naphthalene-disulfonic acid, 2-, 3- or 4-methylbenzenesulfonic acid, methylsulfuric acid, ethylsulfuric acid, dodecylsulfuric acid, N-cyclohexylsulfamic acid, N-methyl-, N-ethyl- or N-propyl-sulfamic acid, and other organic protonic acids, such as ascorbic acid. Suitable inorganic acids are, for example, hydrohalic acids, such as hydrochloric acid, sulfuric acid, and phosphoric acid. [0030] The β-hairpin peptidomimetics of the invention, in free form or in the form of pharmaceutically acceptable salts, or compositions thereof, will generally be used in an amount effective to achieve the intended purpose. It is to be understood that the amount used will depend on a particular application. [0031] For topical administration to treat or prevent HIV infections a therapeutically effective dose can be determined using, for example, the in vitro assays provided in the examples. The treatment may be applied while the HIV infection is visible, or even when it is not visible. An ordinary skilled expert will be able to determine therapeutically effective amounts to treat topical HIV infections without undue experimentation. [0032] For systemic administration, a therapeutically effective dose can be estimated initially from in vitro assays. For example, a dose can be formulated in animal models to achieve a circulating β-hairpin peptidomimetic concentration range that includes the IC 50 as determined in the cell culture (i.e. the concentration of a test compound that is lethal to 50% of a cell culture). Such information can be used to more accurately determine useful doses in humans. [0033] Initial dosages can also be determined from in vivo data, e.g. animal models, using techniques that are well known in the art. One having ordinary skill in the art could readily optimize administration to humans based on animal data. [0034] Dosage amounts for applications as anti-HIV agents may be adjusted individually to provide plasma levels of the ft-hairpin peptidomimetics of the invention which are sufficient to maintain the therapeutic effect. Therapeutically effective serum levels may be achieved by administering multiple doses each day. [0035] In cases of local administration or selective uptake, the effective local concentration of the β-hairpin peptidomimetics of the invention may not be related to plasma concentration. One having the ordinary skill in the art will be able to optimize therapeutically effective local dosages without undue experimentation. [0036] The amount of β-hairpin peptidomimetics administered will, of course, be dependent on the subject being treated, on the subject's weight, the severity of the affliction, the manner of administration and the judgement of the prescribing physician. [0037] The anti-HIV therapy may be repeated intermittently while infections are detectable or even when they are not detectable. The therapy may be provided alone or in combination with other drugs, such as for example other anti-HIV agents or anti cancer agents, or other antimicrobial agents. [0038] Normally, a therapeutically effective dose of the β-hairpin peptidomimetics described herein will provide therapeutic benefit without causing substantial toxicity. [0039] Toxicity of the β-hairpin peptidomimetics of the invention can be determined by standard pharmaceutical procedures in cell cultures or experimental animals, e.g., by determining the LD 50 (the dose lethal to 50% of the population) or the LD 100 (the dose lethal to 100% of the population). The dose ratio between toxic and therapeutic effect is the therapeutic index. Compounds which exhibit high therapeutic indices are preferred. The data obtained from these cell culture assays and animal studies can be used in formulating a dosage range that is not toxic for use in humans. The dosage of the β-hairpin peptidomimetics of the invention lies preferably within a range of circulating concentrations that include the effective dose with little or no toxicity. The dosage may vary within the range depending upon the dosage form employed and the route of administration utilized. The exact formulation, route of administration and dose can be chosen by the individual physician in view of the patient's condition (see, e.g. Fingl et al. 1975, in: The Pharmacological Basis of Therapeutics , Ch. 1, p. 1). [0040] The following Examples illustrate the invention in more detail but are not intended to limit its scope in any way. The following abbreviations are used in these Examples: HBTU: 1-benzotriazol-1-yl-tetramethyluronium hexafluorophosphate (Knorr et al. Tetrahedron Lett. 1989, 30, 1927-1930); HOBt: 1-hydroxybenzotriazole; DIEA: diisopropylethylamine; HOAT: 7-aza-1-hydroxybenzotriazole; HATU: O-(7-aza-benzotriazole-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate (Carpino et al. Tetrahedron Lett. 1994, 35, 2279-2281). 1. Peptide Synthesis Coupling of the First Protected Amino Acid Residue to the Resin [0046] 0.5 g of 2-chlorotritylchloride resin (100-200 mesh, copoly(styrene-1% DVB) polymer matrix, Cat. No. 01-64-0114, Novabiochem, Merck Biosciences Ltd.) (Barlos et al. Tetrahedron Lett. 1989, 30, 3943-3946) (1.4 mMol/g, 0.7 mmol) was filled into a dried flask. The resin was suspended in CH 2 Cl 2 (2.5 ml) and, allowed to swell at room temperature under constant stirring for 30 min. The resin was treated with 0.49 mMol (0.7 eq) of the first suitably protected amino acid residue and 488 μl (4 eq) of diisopropylethylamine (DIEA) in CH 2 Cl 2 (2.5 ml), the mixture was shaken at 25° C. for 4 hours. The resin was shaken (CH 2 Cl 2 /MeOH/DIEA: 17/2/1), 30 ml for 30 min; then washed in the following order with CH 2 Cl 2 (1×), DMF (1×), CH 2 Cl 2 (1×), MeOH (1×), CH 2 Cl 2 (1×), MeOH (1×), CH 2 Cl 2 (2×), Et 2 O (2×) and dried under vacuum for 6 hours. [0047] Loading was typically 0.6-0.9 mMol/g. [0048] The following preloaded resin was prepared: Fmoc-Pro-2-chlorotritylresin. Synthesis of the Fully Protected Peptide Fragment [0049] The synthesis was carried out on a Syro-peptide synthesizer (MultiSynTech GmbH) using 24 to 96 reaction vessels. In each vessel were placed approximately 60 mg (weight of the resin before loading) of the above resin. The following reaction cycles were programmed and carried out: [0000] Step Reagent Time 1 CH 2 Cl 2 , wash and swell (manual) 1 × 3 min. 2 DMF, wash and swell 1 × 60 min.  3 40% piperidine/DMF 2 × 5 min. 4 DMF, wash 5 × 1 min. 5 5 equiv. Fmoc amino acid/DMF + 2 × 60 min.  5 eq. HBTU + 10 eq. DIEA 6 DMF, wash 5 × 1 min. 7 40% piperidine/DMF 2 × 5 min. 8 DMF, wash 5 × 1 min. 9 CH 2 Cl 2 , wash (at the end of the synthesis) 3 × 1 min. [0050] Steps 3 to 6 are repeated to add each amino-acid. Analytical Method: [0051] Analytical HPLC retention times (RT, in minutes) were determined using a Jupiter Proteo 90 A column, 150×2.0 mm, (cod. 00E-4396-B0—Phenomenex) with the following solvents A (H 2 O+0.1% TFA) and B (CH 3 CN+0.1% TFA) and the gradient: 0 min: 95% A, 5% B; 0.5 min: 95% A, 5% B; 20 min: 40% A, 60% B; 21 min: 0% A, 100% B; 23 min: 0% A, 100% B; 23.1 min: 95% A, 5% B; 31 min: 95% A, 5% B. Formation of Disulfide β-Strand Linkage [0052] After completion of the synthesis, the resin was swelled in 3 ml of dry DMF for 1 h. Then 10 eq. of iodine solution in DMF (6 ml) were added to the reactor, followed by stirring for 1.5 h. The resin was filtered and a fresh solution of iodine (10 eq.) in DMF (6 ml) was added, followed by stirring for another 3 h. The resin was filtered and washed with DMF (3×) and CH 2 Cl 2 (3×). Cleavage, Backbone Cyclization, Deprotection and Purification of the Peptide [0053] After formation of the disulfide β-strand linkage, the resin was suspended in 1 ml (0.14 mMol) of 1% TFA in CH 2 Cl 2 (v/v) for 3 minutes and filtered, and the filtrate was neutralized with 1 ml (1.15 mMol) of 20% DIEA in CH 2 Cl 2 (v/v). This procedure was repeated twice to ensure completion of the cleavage. The resin was washed three times with 1 ml of CH 2 Cl 2 . The CH 2 Cl 2 layer was evaporated to dryness. [0054] The volatiles were removed and 8 ml dry DMF were added to the tube. Then 2 eq. of HATU in dry DMF (1 ml) and 4 eq. of DIPEA in dry DMF (1 ml) were added to the peptide, followed by stirring for 16 h. The volatiles were evaporated to dryness. The crude cyclised peptide was dissolved in 7 ml of CH 2 Cl 2 and extracted with 10% acetonitrile in H 2 O (4.5 ml) three times. The CH 2 Cl 2 layer was evaporated to dryness. To deprotect the peptide fully, 3 ml of cleavage cocktail TFA:TIS:H 2 O (95:2.5:2.5) were added, and the mixture was kept for 2.5 h. The volatiles were evaporated to dryness and the crude peptide was dissolved in 20% AcOH in water (7 ml) and extracted with isopropyl ether (4 ml) for three times. The aqueous layer was collected and evaporated to dryness, and the residue was purified by preparative reverse phase HPLC. [0055] After lyophilisation the products were obtained as white powders and analysed by the HPLC-ESI-MS analytical method described above. The analytical data comprising purity after preparative HPLC and ESI-MS are given. Example 1 [0056] The peptide was synthesized starting with the amino acid L-Pro which was grafted to the resin. Starting resin was Fmoc-Pro-2-chlorotrityl resin, which was prepared as described above. The linear peptide was synthesized on solid support according to the procedure described above in the following sequence: Resin-Pro- D Pro-Lys-Gln-Tyr-Cys-Tyr-Arg-Dab- D Pro-Ala-Ser-Cys-Ala-His-Tyr. A disulfide β-strand linkage was introduced as described above. The product was cleaved from the resin, cyclized, deprotected and purified as indicated by preparative reverse phase LC-MS. [0057] After lyophilisation the product was obtained as white powder and analysed by the HPLC-ESI-MS analytical method described above ([M+2H] 2+ : 933.1; RT: 10.47; UV-purity: 72%). Example 2 [0058] The peptide was synthesized starting with the amino acid L-Pro which was grafted to the resin. Starting resin was Fmoc-Pro-2-chlorotrityl resin, which was prepared as described above. The linear peptide was synthesized on solid support according to the procedure described above in the following sequence: Resin-Pro- D Pro-Lys-Gln-Tyr-Cys-Tyr-Arg-Dab- D Pro-Ala-Ser-Cys-Tyr-His-Tyr. A disulfide β-strand linkage was introduced as described above. The product was cleaved from the resin, cyclized, deprotected and purified as indicated by preparative reverse phase LC-MS. After lyophilisation the product was obtained as white powder and analysed by the HPLC-ESI-MS analytical method described above ([M+2H] 2+ : 978.6; RT: 10.95; UV-purity: 82%). 2. Biological Methods 2.1. Preparation of the Peptides. [0059] Lyophilized peptides were weighed on a Microbalance (Mettler MT5) and dissolved in sterile water to a final concentration of 1 mM unless stated otherwise. Stock solutions were kept at +4° C., light protected. 2.2. Ca 2+ Assay: CXCR4-Antagonizing Activity of the Peptides. [0060] Increases in intracellular calcium were monitored using a Flexstation 384 (Molecular Devices, Sunnyvale, Calif.) to assay the peptides for CXCR4 antagonism in a mouse pre-B cell line 300-19 stably transfected with human CXCR4 [see references 1, 2 and 3, below]. The cells were batch loaded with the Calcium 3 Assay kit (Molecular Devices) in assay buffer (Hanks Balanced salt solution, HBSS, 20 mM HEPES, pH 7.4, 0.1% BSA) for 1 h at room temperature and then 200,000 labeled cells were dispensed into black 96 well assays plates (Costar No. 3603). A 20-fold concentrated solution of peptide in assay buffer was added to the cells and the whole plate was centrifuged to settle the cells to the bottom of the wells. Calcium mobilization induced by 10 nM stromal-derived factor-1 (SDF-1) was measured in the Flexstation 384 (excitation, 485 nM; emission, 525 nM) for 90 seconds. A maximal change in fluorescence response above baseline was used to calculate antagonist activity. The data for dose response curves (antagonist concentration versus % maximum response) were fitted to a four parameter logistic equation using SoftmaxPro 4.6 (Molecular Devices), from which IC 50 % values were calculated. 2.3. FIGS-Assay™ [0061] The assay was performed according to ref. 5, below. Stock dilutions of the peptides (10 μM) were prepared by dissolving in 10 μM Tris-HCl at room temperature. Stock solutions were kept at +4° C., light protected. Working dilutions were prepared extemporaneously by serial dilution in Phosphate Buffered Saline (PBS) and added in a final volume of 10 μl directly to the cell cultures. After 48 hours of co-cultivation the cultures were rinsed with PBS and then exposed to glutaraldehyde/formaldehyde (0.2%/2%) in PBS for five minutes. For photometric quantification the fixed cultures were subsequently incubated with ortho-nitro-phenyl-galactopyranoside (ONPG) as a β-galactosidase substrate, which was enzymatically converted into the chromophore ortho-nitrophenol (ONP). The read out is directly obtained by measuring optical density of wells at 405 nm in an iEMS 96 well-plate reader. 2-4. Cytotoxicity Assay [0062] The cytotoxicity of the peptides to HELA cells (Acc57) and COS-7 cells (CRL-1651) was determined using the MTT reduction assay [see ref. 6 and 7, below]. Briefly the method was as follows: HELA cells and COS-7 cells were seeded at 7.0×10 3 and, respectively, 4.5×10 3 cells per well and grown in 96-well microtiter plates for 24 hours at 37° C. at 5% CO 2 . At this point, time zero (Tz) was determined by MTT reduction (see below). The supernatant of the remaining wells was discarded, and fresh medium and the peptides in serial dilutions of 12.5, 25 and 50 μM were pipetted into the wells. Each peptide concentration was assayed in triplicate. Incubation of the cells was continued for 48 hours at 37° C. at 5% CO 2 . Wells were then washed once with PBS and subsequently 100 μl MTT reagent (0.5 mg/mL in medium RPMI1640 and, respectively, DMEM) was added to the wells. This was incubated at 37° C. for 2 hours and subsequently the medium was aspirated and 100 μl isopropanol was added to each well. The absorbance at 595 nm of the solubilized product was measured (OD 595 peptide). For each concentration averages were calculated from triplicates. The percentage of growth was calculated as follows: (OD 595 peptide-OD 595 Tz-OD 595 Empty well)/(OD 595 Tz-OD 595 Empty well)×100% and was plotted for each peptide concentration. [0063] The LC 50 values (Lethal Concentration, defined as the concentration that kills 50% of the cells) were determined for each peptide by using the trend line function of EXCEL (Microsoft Office 2000) for the concentrations (50, 25, 12.5 and 0 μM), the corresponding growth percentages and the value −50, (=TREND(C50:C0,%50:%0,−50)). The GI 50 (Growth Inhibition) concentrations were calculated for each peptide by using a trend line function for the concentrations (50, 25, 12.5 and 0 μg/ml), the corresponding percentages and the value 50, (=TREND (C 50 :C 0 ,% 50 :% 0 ,50). 2.5. Cell Culture [0064] ‘CCR5’ cells were cultured in DMEM medium with 4500 mg/ml glucose, 10% fetal bovine serum (FBS), supplemented with 50 U/ml Penicillin and 50 μg/ml Streptomycin (Pen/Strept.). Hut/4-3 cells were maintained in RPMI medium, 10% FBS, supplemented with Pen/Strept. and 10 mM HEPES. HELA cells and CCRF-CEM cells were maintained in RPMI1640 plus 5% FBS, Pen/Strept and 2 mM L-Glutamine. Cos-7 cells were grown in DMEM medium with 4500 mg/ml glucose supplemented with 10% FCS, Pen/Strept. and 2 mM L-Glutamine. All cell lines were grown at 37° C. at 5% CO 2 . Cell media, media supplements, PBS-buffer, HEPES, Pen/Strept., L-Glutamine and sera were purchased from Gibco (Pailsey, UK). All fine chemicals came from Merck (Darmstadt, Germany). 2.6. Hemolysis [0065] The peptides were tested for their hemolytic activity against human red blood cells (hRBC). Fresh hRBC were washed three times with phosphate buffered saline (PBS) by centrifugation for 10 min at 2000×g. Peptides at a concentration of 100 μM were incubated with 20% v/v hRBC for 1 hour at 37° C. The final erythrocyte concentration was approximately 0.9×10 9 cells per ml. A value of 0% resp. 100% cell lysis was determined by incubation of the hRBC in the presence of PBS alone and respectively 0.1% Triton X-100 in H 2 O. The samples were centrifuged and the supernatant was 20-fold diluted in PBS buffer and the optical density (OD) of the sample at 540 nM was measured. The 100% lyses value (OD 540 H 2 0) gave an OD 540 of approximately 1.3-1.8. Percent hemolysis was calculated as follows: (OD 540 peptide/OD 540 H 2 0)×100%. 2.7. Chemotactic Assay (Cell Migration Assay) [0066] The chemotactic response of CCRF-CEM cells to a gradient of stromal cell-derived factor 1α (SDF-1) was measured using disposable assay plates from Neuroprobe (5μ pore size) (Gaithersburg, Md.), according to the manufacturer's directions and references therein [especially ref. 8, below]. Briefly, one 175 cm 3 flask was washed once with Dubecco's phosphate buffered saline (DPBS), and trypsinized for 10 minutes or until cells had lifted. The trypsin was neutralized by the addition of fresh medium containing serum and the cells were pelleted, washed once in DPBS, and resuspended at 1-0.5×10 7 cells/ml in RPMI+0.5% bovine serum albumin (BSA). 45 μl of cell suspension were mixed with 5 μl of 10-fold concentrated PEM peptide diluted in the same assay medium. 35 μl of this mixture were applied to the top of the assay filter. The cells were allowed to migrate (at 37′) into the bottom chamber of the assay plate containing 1 nM SDF-1. After 4 hours, the filter was removed and MTT was added to the migrated cells to a final concentration of 0.5 mg/ml, and incubated for a further 4 hours. After labeling with MTT, all medium was removed and 100 μl of isopropanol+10 mM HCl were added to the cells. The optical absorbance at 595 nm (ABS 595 ) was read using a Tecan Genios plate reader with Magellan software. The number of cells migrated was determined by comparing ABS 595 values against a standard curve generated with a known number of cells in the assay plate and were plotted against SDF-1 concentration to obtain a sigmoidal curve and to determine the IC 50 values. The values for 1050 were determined using the Trendline function in Microsoft Excel by fitting a logarithmic curve to the averaged datapoints. 2.8 Plasmastability [0067] 405 μl of plasma/albumin solution were placed in a polypropylene (PP) tube and spiked with 45 μl of compound from a 100 μM solution B, derived from 135 μl of PBS and 15 μl of 1 mM peptide in PBS, pH 7.4. 150 μl aliquots were transferred into individual wells of the 10 kDa filter plate (Millipore MAPPB 1010 Biomax membrane). For “0 minutes controls”: 270 μl of PBS were placed in a PP tube and 30 μl of stock solution B was added and vortexed. 150 μl of control solution was placed into one well of the filter plate and serves as “filtered control”. [0068] Further 150 μl of control solution were placed directly into a receiver well (reserved for filtrate) and serve as “not-filtered control”. The entire plate including evaporation lid was incubated for 60 min at 37° C. Plasma samples (rat plasma: Harlan Sera lab UK, human plasma: Blutspendezentrum Zürich) were centrifuged at least for 2 h at 4300 rpm (3500 g) and 15° C. in order to yield 100 μl filtrate. For “serum albumin”-samples (freshly prepared human albumin: Sigma A-4327, rat albumin: Sigma A-6272, all at 40 mg/ml concentration in PBS) approximately 1 hour of centrifugation is sufficient. The filtrates in the receiver PP plate were analysed by LC/MS as follows: Column: Jupiter C18 (Phenomenex), mobile phases: (A) 0.1% formic acid in water and (B) acetonitrile, gradient: 5%-100% (B) in 2 minutes, electrospray ionization, MRM detection (triple quadrupole). The peak areas were determined and triplicate values are averaged. The binding is expressed in percent of the (filtered and not-filtered time point 0 min) control 1 and 2 by: 100−(100*T 60 /T 0 ). The average from these values is then calculated (see ref. 9 below). 3.0 In Vivo Studies 3.1. Maximum Tolerated Dose in Mice [0069] a) The compound of Example 1, dispersed in Water for Injection or 0.9% physiological saline), was administered, in the preliminary study, by i.v. injection at dose levels of 35, 50, 70, 85, 100, 150, 250 or 500 mg/kg to groups consisting of one male and one female mouse (Cr1:CD1(ICR)). In addition, two groups comprising two male and two female mice received dose levels of 90 and 100 mg/kg, respectively, and the 50 mg/kg dose level was repeated in a group comprising one male and one female. b) Maximum tolerated dose studies (MTD) carried out with the compound of Example 2 using CD1 mice (3 mice/group) and was performed using i.v, ip and sc. administration. 3.2 Repeated Toxicity Studies in Mice [0070] The toxicity and toxicokinetics of the compound of Example 1 was investigated following daily i.v. injection in the mouse for at least 14 days. Groups of 12 male and 12 female Cr1:CD1(ICR) mice received dose preparations containing control article (50 mM sodium dihydrogen orthophosphate buffer containing 0.9% w/v sodium chloride) or 8, 24, or 40 mg/kg/day POL6326 at a dose volume of 5 mL/kg. Satellite groups of 24 animals per sex per group were included at each dose level. Assessment of toxicity was based on mortality, clinical signs, body weights, food consumption, ophthalmic examinations, clinical and anatomic pathology, and toxicokinetic evaluations. 3.3 Stemcell Mobilisation a) Mice Model: [0071] The aim of the study was to evaluate the ability of the compound of Example 1 and Example 2 to mobilize hematopoietic progenitors from mouse bone marrow to peripheral blood using in-vitro hematopoietic colony assays. In humans, accurate information about progenitor cell mobilization is provided by the colony forming unit granulocyte-monocyte (CFU-GM) assay or by determining the abundance of CD34(+) cells by FACS analysis (see ref. 10 below). In mice, CD34 is not a useful marker for stem cells; instead the CFU-GM is more commonly used (see ref. 11 below). [0072] In order to assess the ability of the compounds of Example 1 and Example 2 to mobilize murine stem cells (CFU-GM) C3H/HeJ female mice (Jackson Laboratory) were injected s.c. with 5 mg/k, of the compounds of Example 1 and of Example 2 and as reference AMD3100 (Broxmeyer, et al, J Exp Med 201, 1307-1318), (currently undergoing Phase III clinical trials) for stem cell mobilisation. Peripheral blood samples from 5 animals per test group were collected at each time point and nucleated cell counts performed as standard assays. b) Monkey Model: [0073] An assessment of mobilization of peripheral-blood hematopoietic stem cells in cynomolgus monkeys ( Macaca fascicularis ) was performed. The compound of Example 1 was administered to 4 monkeys (2 male and 2 female) as a slow bolus i.v. injection over 2 minutes and CD34(+) cells were determined by FACS analysis. Toxicokinetic blood sampling was also performed. 4.0. Results [0074] The results of the experiments described under 2.2-2.8, above, are indicated in the following Tables 1 and 2. [0000] TABLE 1 Cyto-toxicity Hemo- IC 50 (μM) IC 50 (nM) FIGS LC 50 /GI 50 lysis Cell migration Ex. Ca 2+ assay IC50 (nM) Hela cells at 100 μM assay 1 5.5 n.d. >50 0.6 n.d. 2 4.1 24.7 94 0.3 0.5 n.d.: not determined [0000] TABLE 2 Ex. Stability human Plasma t 1/2 (min) Stability rat Plasma t 1/2 (min) 1 >240 >240 2 >300 >300 [0075] The results of the experiment described in 3.1-3.3 are given herein below. 4.1: MTD Study in Mice a) MTD Study, Compound of Example 1 [0076] The acute minimum lethal intravenous dose level of Ex. 1 in the mouse was found to exceed 90 mg/kg. b) MTD Study, Compound of Example 2 [0077] The highest dose tested for all three routes of administration was 120 mg/kg bolus. At this dose all animals survived and only mild symptoms were observed. The symptoms exhibited were slight behavioral depression, slight cyanosis, an increase in respiratory depth and muscle relaxation. 4.2: 14-Day Intravenous Injection Toxicity and Toxicokinetic Study [0078] The NOAEL level for the compound of Example 1 following i.v. dosing in the mouse was 40 mg/kg/day. [0079] There was no notable effect of treatment on body weight, body weight change, or food consumption, or on ophthalmic observations during the final week of the dosing phase. [0080] Administration of the compound of Example 1 was associated with mildly higher white blood cell and absolute lymphocyte counts for females given 40 mg/kg/day. Males given 40 mg/kg/day were not similarly affected, and these minor effects were not considered adverse. Clinical chemistry results were unaffected by administration of the compound of Example 1. Increases in organ weights (kidneys in males given 8 mg/kg/day and seminal vesicles in males given 24 or 40 mg/kg/day) were considered incidental and unrelated to treatment. No test article-related gross lesions were recorded. Three animals (1 control group female, 1 male at 8 mg/kg/day and 1 female at 24 mg/kg/day) had a focal, red, crusted area at the injection site (tail), which was the result of hypodermic needle punctures. No test article-related microscopic lesions were observed. 4.3: Stemcell Mobilisation a) Stem Cell Mobilization in Mice, Compound of Example 1: [0081] Administration of 5 mg/kg of the compound of Example 1 increased the CFU-GM blood cell numbers with a maximal effect at 120 minutes and return to baseline levels 6 h post administration. ( FIG. 1 ). In the same assay, AMD3100 (currently undergoing Phase III clinical trials for stem cell mobilisation) was used as a comparator. In a follow up study, the dose response of Ex. 1 on the release of CFU-GM was determined ( FIG. 1 ). There is a clear dose response effect of Ex. 1 on the release of CFU-GM in mice with a peak level increase at 5 mg/kg. b) Stem Cell Mobilization in Mice, Compound of Example 2: [0082] Administration of 5 mg/kg of the compound of Example 2 increased the CFU-GM blood cell numbers up to six hours post administration with a maximal effect at 240 minutes whereas administration of AMD3100 is associated with an increase in the frequency and number of progenitors at 30 and 60 minutes compared to control mice ( FIG. 2 ). c) Stem Cell Mobilization in Monkey, Compound of Example 1: [0083] Administration of the compound of Example 1 induced mobilization of CD34(+) hematopoietic cells in cynomolgus monkeys. As observed in mice, the onset of mobilization was rapid with a peak level at two hours. The mobilisation was also transient and the numbers of stem cells in peripheral blood returned to baseline level with decreasing plasma levels of the compound of Example 1 ( FIG. 3 ). REFERENCES [0000] 1. Oberlin E, Amara A, Bachelerie F, Bessia C, Virelizier J-L, Arenzana-Seisdedos F, Schwartz O, Heard J-M, Clark-Lewis 1, Legler D F, Loetscher M, Baggiolini M, Moser B. Nature. 1996, 382:833-835 2. Loetscher M, Geiser T, O'Reilly T, Zwalen R, Baggiolini M, Moser B. J. Biol. Chem. 1994. 269:232-237 3. D'Apuuo M, Rolink A, Loetscher M, Hoxie J A, Clark-Lewis I, Melchors F, Baggiolini M, Moser B. Eur. J. Immunol. 1997. 27:1788-1793 4. von Tscharner V, Prod'hom B, Baggiolini M, Reuter H. Nature. 1986. 324:369-72. 5. Hamy F, Felder E R, Heizmann G, Lazdins J, Aboul-ela F, Varani G, Karn J, Klimkait T. Proc. Natl. Acad. Sci. 1997. 94:3548-3553. 6. Mossman T. J. Immunol. Meth. 1983, 65:55-63 7. Berridge M V, Tan A S. Arch. Biochem. Biophys. 1993, 303:474-482 8. Frevert C W, Wong V A, Goodman R V, Goodwin R, Martin T R, J. Immunol. Meth. 1998. 213: 41-52 9. Singh R., Chang, S. Y., Talor, L. C., Rapid Commun. Mass Spectrom., 1996, 10: 1019-1026 10. To L B, Haylock D N, Simmons P J, Juttner C A. Blood 1997, 89(7):2233-2258. 11. Broxmeyer H E, Orschell C M, Clapp D W, Hangoc G, Cooper S, Plett P A et al. J Exp Med 2005. 201(8): 1307-1318.
The template-fixed B-hairpin peptidomimetics Cyclo(-Tyr-His-X-Cys-Ser-Ala- D Pro-Dab-Arg-Tyr-Cys-Tyr-Gln-Lys- D -Pro-Pro), disulfide bond between Cys4 and Gys11, and pharmaceutically acceptable salts thereof, with X being Ala or Tyr, have CXCR4 antagonizing properties and can be used for where cancer is mediated or resulting from CXCR4 receptor activity
2
Priority to German Patent Application No. 100 60 826.4, which is hereby incorporated by reference herein, is hereby claimed. BACKGROUND OF THE INVENTION The present invention relates to a spring element for fixing in place printing forms on printing form cylinders which are contained in printing units of rotary printing presses, the printing forms being printing forms which have a plate-shaped configuration and feature angularly bent leading edges and trailing edges. European Patent No. 0 534 579 B2 relates to a device for changing printing plates in a rotary printing press. In this design approach, provision is made for a plurality of leaf springs which are each formed of a leaf spring member and have a U-shaped cross-section. These leaf springs are accommodated in a spring groove. The leaf springs each include a leg via which the leading end of the printing plate is retained in the clamping channel; the leaf springs, moreover, include a second leg via which an angularly bent trailing printing plate edge is fixed in place in the clamping channel of the printing form cylinder. A tensioning spindle is acted upon by a preloading element so that the tensioning spindle can be moved is such a manner that the leaf springs can act both upon a leading edge and upon a trailing edge of a printing plate. The leaf spring arrangement known from European Patent EP 0 534 579 B2 involves the disadvantageous circumstance that, due to the narrow installation space, the leaf springs cannot be fitted into a preassembled tensioning shaft which is already integrated into the printing form cylinder. SUMMARY OF THE INVENTION In view of the indicated related art, an object of the present invention is to provide a spring element which is easy to mount and dismount, for fixing in place printing forms on cylinders. According to the present invention, this objective may be achieved by a device or fixing printing forms on printing form cylinders of rotary printing presses, the printing forms extending into a clamping channel with their leading edges and trailing edges and, via clamping elements in the clamping channel, being tensioned on the lateral surface of the printing form cylinder in a circumferential direction of the printing form cylinder and retained in the clamping channel. The clamping elements are accommodated on a tensioning shaft which is rotatably accommodated in a bore of the printing form cylinder, and the clamping elements are designed as Y-shaped spring elements including a first and a second resilient section. The advantages which can be attained using this design approach are to be seen above all in that a tension spring element configured in this manner needs an extremely small installation space and that it can be installed after the tensioning spindle has already been introduced into the receiving bore in the printing form cylinder accommodating the printing form. This involves that the installation work is made easier and rationalized; moreover, the spring element configured according to the present invention for fixing in place printing forms can be replaced in the clamping channel of a printing form cylinder easily. During the replacement of the clamping elements configured according to the present invention, it is not required to remove the cylinder from the side walls of the printing unit, which would result in unjustifiably long standstill times (downtime) of the respective printing unit. A further advantageous aspect of the design approach according to the present invention is to be seen in that a spring element having the design proposed according to the present invention allows both the printing form to be tensioned in a circumferential direction on the lateral surface of the respective printing form cylinder and the leading printing form edge to be fixed in place on a side wall of the clamping channel concurrently with the tensioning of the trailing printing form edge. The configuration of a spring element according to the present invention makes it possible for the printing form ends to be fixed in place in the clamping channel, involving a high retention force, while at the same time permitting compensating movements of the printing form on the lateral surface due to the flexural elasticity of the clamping element configured according to the present invention. In an advantageous refinement of the idea of the present invention, a plurality of spring elements can be accommodated side by side in the clamping channel of the respective printing form cylinder. This permits an easy mounting or dismounting of the spring elements on printing units of rotary printing presses which contain extremely slender and therefore relatively wide printing form cylinders. A first variant of an embodiment of the spring elements configured according to the present invention includes a first and a second resilient section made of flexurally elastic material of different material thickness. In this context, in a particularly simple manner in terms of production engineering, the first and the second resilient section can be made of materials of different material thickness which are joined to form a spring element configured according to the present invention, the spring qualities of the spring element being adjustable through the selection of the material thickness. Thus, for instance, the first resilient section which tensions the trailing edge of a printing form in a circumferential direction on the lateral surface of a printing cylinder can be designed with a higher, a greater material thickness in comparison with the second resilient section of the spring element projecting from the first resilient section in a Y-shaped manner. To improve the transfer of the retention force, the first resilient section designed with a greater material thickness is provided with an angularly bent, hook-shaped end region via which the trailing edge of the printing form to be fixed in place on the lateral surface of the printing form cylinder is grasped and tensioned in a circumferential direction. Because of the flexural elasticity inherent in the first resilient section, the tensional force is permanently transferred to the printing form when the spring element is in a tensioning position. At a spreading location, the second resilient section of the spring element branches off from the first resilient section in a Y-shaped fashion in a manner which reduces the required installation space. Because of this, the spring element configured according to the present invention can be inserted into the clamping channel provided on the printing form cylinder with the locating section ahead which can easily be introduced into the receiving slot of the tensioning shaft which accommodates and actuates the spring element. The second resilient section projecting from the first resilient section in a Y-shaped manner includes a curved region at whose side facing the leading edge of the printing form, a linear contact region is formed. Via the linear contact region, the second section abuts against the leading edge of the printing form retained on a side wall of the printing form cylinder and fixes the leading edge permanently in place in the clamping channel while, at the same time, the first resilient section grips under the trailing edge of the printing form with its hook-shaped end, tensioning the printing form in a circumferential direction on the lateral surface of the printing form cylinder. In addition to configuring the second resilient section of the spring element in a manner that a linear contact with the leading printing form edge is provided, this section can also be provided with coatings which increase the coefficient of friction, pin-shaped retaining elements extending through the angularly bent leading printing form edge, thus fixing in place the leading edge on a side wall of the clamping channel in the printing form cylinder. In a further variant of an embodiment of the spring element configured according to the present invention, the spring element can be designed in one piece with a continuous locating section from which first and second resilient sections project in a Y-shaped manner. In this variant of an embodiment of the spring element proposed according to the present invention, the first and second resilient sections can be alternately formed on a workpiece in a segment-like manner. The first and second resilient sections are separated from each other by slot-shaped openings so that the one-piece spring element is easy to manufacture in terms of production engineering, using simple forming processes. In this context, according to the second variant of the design approach of the present invention, the end of the first resilient section of the spring element designed in one piece which end grasps the trailing edge of the printing form can be provided with a rounded region which reduces the risk of injury to the person who manually changes the printing form. Besides, the spring elements configured according to the present invention can, of course, also be used for retaining, tensioning and fixing in place plate-shaped printing forms which can be conveyed to the printing form cylinders of rotary printing presses or removed therefrom via automatic or semi-automatic printing plate changing devices. The design approach proposed according to the present invention, can preferably be used on rotary printing presses, it being particularly preferred for use in web-fed rotary printing presses, for example short-run or newspaper presses. BRIEF DESCRIPTION OF THE DRAWING In the following, the present invention will be explained in detail with reference to the drawings in which: FIG. 1 provides an enlarged-scale view of a clamping channel for receiving the leading and trailing edges of the printing form; FIG. 2 shows a spring element formed in one piece, featuring a continuous locating section for the fastening on a tensioning shaft; FIG. 3 depicts the spring element configured according to the present invention in an untensioned condition; FIG. 4 is a view of the spring element designed according to the present invention in a first position tensioning the trailing printing form edge in a circumferential direction of the printing form cylinder; and FIG. 5 shows the spring element made according to the present invention in a second tensioning position jointly fixing in place the leading printing form edge and the trailing printing form edge. DETAILED DESCRIPTION The representation according to FIG. 1 illustrates in greater detail a clamping channel for the leading and trailing printing form edges, the clamping channel being represented at an enlarged scale. A flexible, plate-shaped printing form 10 is accommodated on a lateral surface 2 of printing form cylinder 1 . A leading edge 12 and a trailing edge 13 of printing form 10 extend into a clamping channel 3 in printing form cylinder 1 , the clamping channel being bounded by channel walls 4 . Clamping channel 3 has a cross section having a more or less trapezoidal shaped profile, clamping channel 3 opening in a direction toward tensioning shaft 6 . Clamping channel 3 is bounded at the bottom side by a tensioning shaft 6 in which a receiving slot 7 is formed. Receiving slot 7 is bounded by lateral contact surfaces 8 between which a continuous locating section of a one-piece spring element 27 or the locating sections of a plurality of spring elements 16 arranged side by side in clamping channel 3 are accommodated. The direction of rotation of printing form cylinder 1 , whose lateral surface 2 accommodates printing form 10 , is denoted by the arrow provided with reference numeral 5 . A radius 9 bounding the aperture of clamping channel 3 at lateral surface 2 of printing form cylinder 1 constitutes the location where leading edge 12 of printing form 10 is hung into place at a channel wall 4 of clamping channel 3 . Printing form surface 11 of printing form 10 transfers the print image transferred thereto to the transfer cylinder which, in turn, transfers the print image to the stock, for instance, a continuous material web. The representation according to FIG. 1 illustrates that a spring element 16 designed in Y-shape 21 is inserted in receiving slot 7 of tensioning shaft 6 . This variant of an embodiment of the present invention includes spring element 16 having a first resilient section 17 and a second resilient section 19 . First resilient section 17 and second resilient section 19 are each formed with different material thickness 20 . 1 and 20 . 2 , respectively. First resilient section 17 and second resilient section 19 can be manufactured from different materials, respectively, which are joined via a joining operation to form a spring element 16 . In the process, it is possible to provide both first resilient section 17 and second resilient section 19 with an individual flexural elasticity via the selection of material thickness 20 . 1 and 20 . 2 . Y-shape 21 makes it easier for spring element 16 to be inserted into receiving slot 7 of tensioning shaft 6 . Y-shape 21 is impressed on spring element 16 at a spreading location 26 at which second resilient section 19 branches off from first resilient section 17 at an angle of 10 to 30°. Depending on the selection of the angle of spread at spreading location 26 , it is possible to predetermine the preloading of second resilient section 19 relative to first resilient section 17 of spring element 16 . At its end gripping under a trailing edge angle 15 of trailing edge 13 of printing form 10 , first resilient section 17 is angularly bent and provided with a hook-shaped curvature 18 . Because of this, it is ensured that trailing printing form edge 13 is reliably grasped and tensioned in a circumferential direction on lateral surface 2 of printing form cylinder 1 . Second resilient section 19 , which is formed with a smaller material thickness 20 . 2 compared to material thickness 20 . 1 of first resilient section 17 , is configured to include a curved region 23 . The side of curved region 23 facing leading edge 12 of printing form 10 constitutes a contact line 24 of second resilient section 19 with leading edge 12 at a contact region 22 through openings 25 . Contact line 24 on second resilient section 19 can be provided with a coating which improves the coefficient of friction; besides, pin-shaped projections can be attached in the region of contact line 24 which are capable of extending through openings in leading printing form edge 12 which openings can optionally be formed therein for improving the fixing in place of leading printing form edge 12 on side wall 4 of clamping channel 3 . The narrower the aperture of clamping channel 3 between radii 9 at lateral surface 2 of clamping channel 3 is configured, the smaller is non-printing region 14 which forms between angularly bent leading printing form edge 12 and trailing printing form edge 13 . The representation according to FIG. 2 illustrates in greater detail a spring element formed in one piece, featuring a continuous locating section for the fastening on the tensioning shaft in the printing form cylinder. In place of spring elements 16 depicted in FIG. 1 which are arranged side by side in a clamping channel 3 , it is also possible to insert therein a one-piece spring element 27 which features a continuous locating section 28 . This spring element 27 can have first resilient sections 17 and second resilient sections 19 alternately formed thereon in a segment-like manner. On spring element 27 designed in one piece, first and second sections 17 and 19 are separated from one another preferably by openings extending in a slot-shaped manner which are particularly easy to produce in terms of production engineering. Spring element 27 designed according to the variant of an embodiment in FIG. 2 is also substantially Y-shaped which is why it can be easily mounted in receiving slot 7 of a tensioning shaft 6 with smallest installation space requirements. Spring element 27 designed in one piece can likewise be inserted into a tensioning shaft 6 which is already accommodated in a bore of printing form cylinder 1 . According to the variant of an embodiment of the spring element in FIG. 2, the ends of first resilient sections 17 are provided with rounded regions 29 so that during the handling of the spring element 27 configured in one piece with a continuous locating section, the risk of injury to the person handling it is markedly reduced. Subsequent to producing slot-shaped openings 31 through window or cut-out 30 , spring element 27 configured in one piece can be manufactured by way of cold forming in a simple manner in terms of production engineering, the material thickness of first and second sections 17 and 19 being identical according to this variant of an embodiment of the spring element. FIG. 3 illustrates in greater detail the spring element configured according to the present invention in an untensioned condition. Untensioned position 34 of spring element 16 , 27 designed in Y-shape 21 is denoted by reference numeral 34 . Spring element 16 , 27 is inserted into receiving slot 7 of tensioning shaft 6 via its locating section. Trailing printing form edge 13 of printing form 10 to be tensioned in a circumferential direction on lateral surface 2 of printing form cylinder 1 is not yet grasped by curved, hook-shaped end 18 of first resilient section 17 . Likewise, second resilient section 19 does not yet abut, via its linear contact region 24 opposite of curvature region 23 , against leading edge 12 to be fixed in place of printing form 10 while spring element 16 , 27 is in untensioned condition 34 . In untensioned condition 34 of spring element 16 or 27 , first resilient section 17 and second resilient section 19 are still undeformed relative to each other referred to spreading location 26 , since no forces act upon first or second resilient section 17 , 19 of spring element 16 , 27 yet. Only when clamping shaft 3 is rotated counterclockwise in the direction of arrow 33 , spring element 16 , 27 designed in Y-shape 21 is converted from untensioned condition 34 into a first tensioning position 36 according to FIG. 4 . The representation according to FIG. 4 illustrates in greater detail the spring element designed according to the present invention in a first position tensioning the trailing edge of the printing form in a circumferential direction on the printing form cylinder. In comparison with FIG. 3, in the condition given in FIG. 4, a rotation of clamping shaft 6 , with spring element 16 , 27 configured according to the present invention being accommodated in receiving slot 7 , has taken place in tensioning direction 33 of clamping shaft 6 so that the shaft is rotated counterclockwise about its axis 32 . The then attained first tensioning position of spring element 16 , 27 configured according to the present invention is denoted by position 36 and characterized in that hook-shaped end 18 of first resilient section 17 has grasped trailing edge angle 15 of printing form 10 , tensioning it in a circumferential direction on lateral surface 2 of printing form cylinder 1 . Accordingly, trailing edge 13 of printing form 10 is drawn onto clamping channel radius 9 in the direction of clamping channel radius 9 which is covered by leading edge 12 of printing form 10 . In first tensioning position 36 , the side of second resilient section 19 opposite of curved region 23 of this section just touches leading printing form edge 12 at contact region 22 which lies against a side of clamping channel 3 . This contact position is denoted by reference numeral 37 . When rotating clamping shaft 6 further in tensioning direction 33 , second resilient section 19 moves toward first resilient section 17 of spring element 16 , 27 which grasps the trailing edge with its hook-shaped end 17 , referred to spreading location 26 , compare FIG. 5 . For the sake of completeness, it should be mentioned that clamping shaft 6 is accommodated at its ends at the end face of a printing form cylinder 1 via a clamping 35 , for example, in the form of a clamping screw. The representation according to FIG. 5 illustrates in greater detail the spring element configured according to the present invention in a second tensioning position which jointly fixes in place the leading edge and the trailing edge of the printing form. Compared to first tensioning position 36 , in the second tensioning position denoted by reference numeral 38 , a further rotation of clamping shaft 6 has taken place in tensioning direction 33 about axis 32 of clamping shaft 6 . Trailing edge 13 of printing form 10 is tensioned by hook-shaped end 18 in a circumferential direction relative to lateral surface 2 of printing form cylinder 1 . In second tensioning position 38 , second resilient section 19 makes contact with leading edge 12 of printing form 10 through openings 25 which leading edge lies against channel wall 4 . Via second resilient section 19 of Y-shaped spring element 16 , 27 , a retention force is imposed on leading edge 12 of printing form 10 , retaining leading edge 12 of printing form 10 on channel wall 4 of clamping channel 3 . In second tensioning position 38 , resilient section 19 has moved toward first resilient section 17 referred to spreading location 26 and, via its inherent flexural elasticity, retains leading edge 12 at tensioning position 39 in its position on channel wall 4 of clamping channel 3 . In this second tensioning position 38 , tensioning shaft 6 is locked so that, via the elasticity inherent in spring element 16 , 27 configured in Y-shape 21 , both trailing edge 13 of printing form 10 is permanently maintained tensioned in a circumferential direction on lateral surface 2 of printing form cylinder 1 and, at the same time, leading edge 12 of printing form 10 is maintained permanently fixed in place on channel wall 4 below clamping channel radius 9 . During a rotation of printing form cylinder 1 with printing form 10 accommodated on lateral surface 2 being tensioned, ends 12 and 13 of printing form 10 , whose surface 11 transfers the print image, are not able to move out of clamping channel 3 in a radial direction. List of Reference Numerals 1 Printing form cylinder 2 Lateral surface 3 Clamping channel 4 Channel wall 5 Direction of rotation 6 Tensioning shaft 7 Receiving slot 8 Contact surface 9 Clamping channel radius 10 Printing form 11 Printing form surface 12 Leading edge 13 Trailing edge 14 Non-printing region 15 Trailing edge angle 16 Spring element 17 First resilient section 18 Hook-shaped end 19 Second resilient section 20 . 1 Material thickness of first resilient section 20 . 2 Material thickness of second resilient section 21 Y-shape 22 Contact region of leading edge 23 Curvature region 24 Contact line 25 Openings of leading printing form edge 26 Spreading location 27 Segmented spring element 28 Locating section 29 Rounded end 30 Window or cut-out 31 Slot-shaped openings 32 Axis of tensioning shaft 33 Tension direction of tensioning shaft 34 Untensioned position 35 Clamping 36 First tensioning position 37 Contact position 38 Second tensioning position 39 Tensioning position
A device for fastening printing forms (10) on printing form cylinders (1) of rotary printing presses. The printing forms (10) extend into a clamping channel (3) with their leading edge (12) and their trailing edge (13) and are tensioned therein, via clamping elements, on the lateral surface (2) of the printing form cylinder (1) in a circumferential direction of the printing form cylinder (1) and retained in the clamping channel (3). The clamping elements are accommodated on a tensioning shaft (6) which is rotatably inserted in a bore of the printing form cylinder (1). The clamping elements are designed as spring elements (16, 27) in Y-shape (21), including a first and a second resilient section (17, 19).
1
BACKGROUND AND SUMMARY OF THE INVENTION This invention relates to refrigerator units and food preparation tables where foodstuffs are kept in separate trays for use by the food preparer and served to a customer, and more particularly to an arrangement in such units for circulating cooling air to maintain a low temperature in the food trays. In commercial fast food establishments certain foods, such as sandwiches, pizza, or salads, are prepared in volume quantities, which requires convenient access by the preparer to ingredients or condiments. These condiments are kept in separate trays for use by the food preparer for assembly into the finished foodstuff. The preparer works at a "make-up" table where the separate ingredients are combined into the finished food product. A typical food preparation table is self-contained, counter top height and formed from thermally insulated stainless steel walls into a generally oblong shaped cabinet. The cabinet includes a refrigeration unit and a chamber for storing and cooling food items. The top wall of the cabinet defines the table, is upwardly open, and has openings for receiving one or more of the foodstuff trays. The trays have their heat transferring bottom and sidewalls extending into the chamber to be cooled by a fan forcing refrigerated air around the bottom portions of the pans. The flow of air and possible loss of velocity head when cooling air must pass long distances may lead to nonuniform chamber cooling and nonuniform cooling of foodstuffs in the tray. Existing food industry standards set by the National Sanitation Foundation ("NSF") require that a refrigeration unit simultaneously maintain the temperature of food in the tray at 45° F for a prolonged period and with minimum dehydration, and the temperature in the chamber at 40° F. (4° C.) with a maximum of compressor run time of 70 percent in a 100° F. (38° C.) ambient environment, such as found in a pizza restaurant. NSF has recently established a new and stricter standard that a refrigerated food preparation table be capable of taking a food product at 38° F. and maintaining it for a period of four hours between 33°-40° F. (about 4° C.) in a room where the ambient temperature is 100° F. (about 38° C.). Food preparation tables known in the prior art cannot always keep up with the product heat gain in such environment. Further, local health codes regulating the operation of food establishments typically require that the temperature of food ingredients be maintained at about 40° F. so that bacteria growth and risk of food poisoning is reduced. Perishable foodstuffs must be maintained at about 40° F. to reduce food spoilage whereas ambient kitchen temperatures can exceed 85° F. (29° C.). It is a principal object of this invention to provide a self-contained counter top refrigerator unit, operative as a food preparation table, wherein a controlled circulation of refrigerated air maintains both the refrigerator chamber and the condiments and/or ingredients in the separate trays extending into the chamber, at a uniform refrigerated temperature. Another object of this invention is provision of a uniquely configured baffle plate to simultaneously direct refrigerating air at all of the condiment trays. Another object of this invention is provision of a horizontal self-contained counter-top upwardly open food preparation table which achieves the above requirements as to control of temperature in a food pan as well as providing cooled air into the foodstuff chamber. In accordance with this invention there is provided a refrigerated food preparation table including an oblong cabinet forming a horizontal table and having an interior cooling chamber, an arrangement for supporting condiment trays on the table such that the lower portions of the trays are positioned in the chamber, and a refrigeration system including a compressor, a condenser, an evaporator coil to refrigerate air in the cooling chamber, a row of fans to circulate air through the chamber and draw chamber air through the evaporator, and refrigerant coils for passing refrigerant through the components of the refrigeration system for connecting the refrigerator components into a refrigeration cycle. Further, an insulated compartment is formed in the chamber adjacent to the rear wall thereof for receiving the compressor and condenser, the rear wall being proximate to the compressor for venting heated compressor air, and a partition wall of the compartment separating the evaporator from the other refrigeration equipment. The evaporator coil is supported in the cooling portion of the chamber. A particularly constructed baffle is mounted in the cooling chamber for directing the flow of refrigerated air within the chamber and about the lower portions of the condiment trays. The baffle extends laterally between the opposite vertical sidewalls of the chamber and includes a first wall which is spaced above the compartment, a second wall which forms a first plenum above the evaporator, and a third wall which cooperates with a flange therefrom to form a second plenum adjacent to the rear wall of the cabinet, the first and third walls being generally vertically extending and the second wall being generally horizontally extending. The first wall is provided with an angled flange to define a suction inlet above the partition wall which supplies recirculated air to the evaporator. The second wall is provided with an array of openings in the form of elongated louvers which ar configured to direct air vertically from the first plenum and primarily against the bottom of the condiment trays. The third wall is provided with an array of generally square openings which are configured to direct air horizontally from the second plenum and primarily against the sidewalls of the trays and into the chamber. Advantageously, the baffle cooperates with the evaporator and evaporator fans to provide refrigerant air in an amount sufficient to cool yet not freeze food in the condiment tray. Further, the baffle openings substantially simultaneously provide cooling air both to all of the condiment trays and to the chamber. Proximate location of the baffle openings adjacent to the trays assure uniform heat transfer relation to the foodstuffs in the trays while other cooling air simultaneously is passed directly into the chamber for cooling the stored foodstuffs. Further, the baffle openings are configured and positioned to direct the cooling air at a desired location such that the desired temperature of the food in the condiment pans is maintained. Efficiency of the baffle correlates into efficiency of the cooling, whereby the refrigerator unit does not have to cycle as frequently, thereby reducing operating costs. The foregoing and other objects and advantages of this invention will become more apparent when viewed in light of the accompanying drawings and following detailed description of the invention in which: BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a front perspective view of a refrigerator, useful as a food preparation table, embodying the invention; FIG. 2 is a side elevation view in section of the food preparation refrigerator table; FIG. 3 is a front partial disassembly view in perspective showing an air circulating baffle and evaporator fan support arrangement, according to the present invention; and FIG. 4 is a side view taken along line 4--4 of FIG. 3 of the air circulating baffle. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Turning now to the drawings, FIGS. 1-4 show a food preparation refrigerator table 10 which comprises a generally rectangular cabinet 12 having a refrigeration system 14 integrally operative therewith, the cabinet having a horizontal, counter top height, food preparation area 16, an interior chamber 18 for storing and cooling foods, a door 20 for gaining access to the chamber, and a top lid 22 for covering at least a part of the table top. The cabinet comprises a base 24, an upper table 26 having a support area for supporting a plurality of condiment trays 28 and defining the food preparation area, a pair of sidewalls 30 and 32, a rear end wall 34, and a front wall 36 for supporting the door, the cabinet walls 30, 32, 34 and 36 extending vertically between the base 24 and the table 26 and defining the interior chamber 18. The cabinet walls are thermally insulated, preferably formed of spaced sheets of stainless steel, with the area between the sheets being filled with a suitable thermally insulated material, such as polyurethane, foamed in place. The table 26 defines a top upwardly open portion of the cabinet and includes a plurality of rails 38 which form openings 40 sized for receiving and supporting one or more upwardly open condiment trays or pans 28 of various sizes useful in storing food to be dispensed. The trays shown are generally rectangular and include four sidewalls 42 each having a lip 44 for supporting the tray on a rail, and a flat base 46, the lower portion of the trays extending into the chamber so as to be maintained in a refrigerated environment. The top lid 22 of the cabinet 12 is adapted to be closed in covering relation with the food in the trays. A bottom machine compartment 48 is formed in a lower corner of the chamber adjacent to the rear wall 34 thereof and extends laterally between the opposite sidewalls 30 and 32 of the chamber. The compartment includes a horizontal partition wall 50 which is connected to the rear wall 34 of the cabinet, and a vertical partition wall 52 which is connected to the base 24, the opposite ends of the partitions 50 and 52 being connected to the sidewalls 30 and 32 and respective edges of the partitions being adjoined to define a chamber 49 that is sealed from the chamber 18 environment. The refrigeration system 14 includes a compressor 54, a condenser 56, a condenser fan (not shown), which are enclosed in the chamber 49, and an evaporator coil 58 to cool chamber 18. Copper tubing 60 connects the flow of refrigerant between the compressor, the condenser and the evaporator to effect a refrigeration cycle. While not shown, access to the machine compartment is provided to enable the user to service the refrigeration equipment. Preferably, the lowermost portion of rear wall 34 adjacent to the compartment would include a grille to pass heat generated by the operation of the compressor. The evaporator coil 58 is supported above the machine compartment so as to have its lower portion 62 spaced vertically above the horizontal partition 50 and its upper portion spaced vertically below a row of evaporator fans 64. A horizontally extending fan support bracket 66 is disposed vertically above the evaporator coil and extends laterally between the sidewalls 30 and 32 of the chamber for connection thereto. Evaporator fans 64 are supported on the support bracket so as to be generally uniformly spaced thereacross and between the sidewalls, the fan blades 68 being positioned directly above the evaporator coil whereby to draw air vertically upwardly therefrom and direct air vertically upwardly. The fan motors (not shown) extend downwardly from the support bracket towards the evaporator. A thermostat (not shown) is connected to the evaporator coil and is electronically connected to a controller (not shown) for operating the refrigeration system. These elements are not shown as being known in the art. When the temperature of the evaporator falls below a desired temperature, a signal is sent to the controller whereby to operate the compressor and to pump refrigerant through the evaporator coil to provide more cool air. In accordance with this invention there is provided a baffle 70 for directing air within the refrigerant chamber 18 to assure cooling air is circulated as needed whereby to maintain the food in the condiment pans at a desired temperature. In the embodiment shown, the baffle 70 is integrally formed from a flat sheet of material and sized to extend laterally between the opposite interior sidewalls of the cabinet for connection thereto. The baffle comprises three generally planar walls or plate portions, including a first wall 72, a second wall 74, and a third wall 76. The first wall 72 is generally disposed in a vertical plane, extends vertically upwardly from the machine compartment 48, and has its lowermost edge 75 spaced from the machine compartment. A longitudinally extending marginal end portion of the first wall forms a flange portion 78 that is disposed at approximately 45° to the vertical plane of the wall and terminates in the edge 75. Advantageously, flange portion 78 cooperates with horizontal partition 50 of the machine compartment to form an air suction inlet 80 whereby to supply air from chamber 18 to lower end 62 of the evaporator 58, and a deflector to inhibit possible water formation from the evaporator coils from entering the foodstuff chamber. The row of evaporator fans 64 act to lower the pressure adjacent the lower end portion 62 of the evaporator 58 and thereby draw the air into the inlet 80. The flange portion 78 defines a venturi which increases the velocity of chamber air and thus the velocity of air discharged upwardly to the second and third walls 72 and 74. Second wall 74 is generally horizontally disposed and is spaced vertically above evaporator coil 58 to define an air plenum 82 directly above the row of evaporator fans. Second wall 74 is proximate the base surfaces 46 of the condiment trays 28 and is provided with a plurality of longitudinally extending, axial, rectangular-shaped openings 84 which direct cooled air from the evaporator fans vertically towards the condiment pans. Preferably, the openings 84 are shown as comprising a plurality of louvers, arranged on a rectangular grid, which result from the sheet material forming the second wall being stamped or formed from any conventional process. Although the louvers are shown extending only in a direction upwardly from the sheet material, it is to be understood that the forming process could result in the louvers being directed only inwardly of the sheet and towards the fans, or directed in both directions from the sheet. The louvers include a sheet portion 86 which is at an acute angle to the plane of the sheet whereby to desirably direct the air without diminishing or diffusing the velocity head. Third wall 76 is generally vertically disposed and extends vertically upwardly from second wall 74 at approximately 10°-15° to a vertical plane. A horizontally disposed flange portion 88 extends from the third wall as a continuation thereof for connection to the interior rear wall 34 of the cabinet. Desirably, flange portion 88 spaces third wall 76 from the rear wall 34 of the cabinet whereby to define a vertical air plenum 90 therebetween. The third wall is proximate the sidewalls 42 of the condiment trays 28 and is desirably formed to include a plurality of generally square-shaped openings 92 which direct cooled air directly from the plenum 90 and against the trays. Preferably in accordance with one embodiment of this invention, support bracket 66 is about 34 inches by 5 inches (170 sq. inches) and supports four fans 64 about 2.5 inches below second wall 74 to draw air vertically from evaporator coil 58 and force cool air into the two plenums 82 and 90 thereabove. The fans are longitudinally aligned in a row across the bracket, each fan having a blade diameter of about 4.5 inches and a motor capable of delivering an output of about 460 cfm. Second wall 74 is about 40.75 inches by 3.43 inches (140 sq. inches) and centered in parallel relation above support bracket 66. A patch of 21 louvers 84 are disposed on a rectangular grid (7 longitudinally spaced in side by side relation and 3 deep). Each louver extends upwardly from second wall at about 25°-40° thereto with a preferred angle being about 30°. Each louver defines a generally rectangular opening having a long dimension that is about 4 inches long and a short dimension that is about 0.1875 inch wide, for an opening area of about 0.75 sq. inches (total flow area of 15.75 sq. in.). The bottom edge 75 is about 0.5 inch from machine compartment wall 50 to define the air suction inlet. Third wall is about 40.75 inches by 3.62 inches (147.7 sq. inches) and includes an array of 135 openings 92 that are disposed on a rectangular grid (45 longitudinally spaced in side by side relation and 3 deep). Each opening 92 is generally square and has an area of 0.25 sq. inches (total flow area of 33.75 sq. in.). The total area for passing air through the openings 92 in third wall 76 is approximately twice the area defined through the louvers 84 in second wall 74. The total velocity head of refrigerant air is about 350-400 ft./min. with 350 ft./min. being preferred in the embodiment shown. In operation, the thermostat control "reads" the evaporator temperature and sends a signal to a controller of the refrigeration system, whereby the coolant is driven through the evaporator and the four fans are driven to draw new cooled air vertically from the suction inlet and direct air at the inwardmost portions of the condiment trays. The baffle orientation relative to the pans causes a constant "blast" of chamber air to be directed at and about the pans. The recirculation path also serves to maintain foodstuffs stored in the chamber in a refrigerated state. As particularly is shown in reference to FIG. 4, the air is caused not only to recirculate but substantially simultaneously provide cool air to the chamber and against all of the sidewalls and bottom walls of trays. It is believed that the configuration of second wall 74 relative to rear wall 34 increases the pressure in plenum 90 such that both direct and reflected velocity air is directed through openings 92. As such, cool air is simultaneously passed between each of the side by side trays, whereby to cool one sidewall directly and two sidewalls indirectly as the air is passed directly into the chamber to cool the foodstuffs therein. Thus, there is disclosed in the above-description and in the drawings and embodiment of the invention which fully and effectively accomplishes the objects thereof. However, it will be apparent to one skilled in the art that variations in the details of the apparatus may be indulged in without departing from the invention herein described, or the scope of the appended claims.
A commercial food preparation refrigerator unit, comprising a food storage chamber disposed under a food preparation table and in which a unique baffle controls circulation of refrigerated air whereby to maintain condiments and/or ingredients in the chamber and foodstuffs in separate trays extending from the table into the chamber, at a uniform refrigerated temperature.
5
[0001] The present invention relates to an improved gutter system and, in particular, to a gutter system that is pivotable from a first position to receive rain water or melted snow, to a second position to facilitate cleaning and maintenance of the gutter, and vice versa. BACKGROUND OF THE INVENTION [0002] Homes and other buildings are typically constructed having some form of gutter system which serves to collect rain water or other liquid from the roof and direct that water away from the house. A gutter generally comprises a longitudinal, rigid structure having a channel extending the length of the gutter. Typical styles of gutters that are available in Australia include D-gutters, fascia gutters, halfround gutters and O.G. gutters which each serve the same purpose but are each contoured slightly differently. Generally, a first longitudinal side of the gutter is directly mounted to a fascia or other like structure immediately underneath the edge of a roof, and the opposed side generally terminates into a rounded edge. When water enters the channel, it is typically directed away from the gutter through one or more downpipes at its ends. It is to be understood that the scope of the present invention is not to be limited to any particular style of gutter, and although the description and drawings relate specifically to D-gutters, the system may well be altered to accommodate for other rain gutter types such as the others mentioned above. [0003] It is well known that gutter systems must be cleaned and maintained at constant intervals in order to avoid certain problems that may arise including gutter leakage, gutter damage and general clogging of the gutter channel and downpipe with foreign debris. For example, when build-up of foreign matter, such as leaves, occurs within a gutter channel or downpipe, the transport of water away from the gutter is restricted resulting in water build-up. Eventually, this build-up of water may lead to potentially larger problems such as water entering the attic, seepage of the water through the walls near the cornices, or damage to objects adjacent the gutter. Also, if the gutters are ‘wet’ for a long time, this increases the susceptibility to corrosion of the gutter. [0004] There have been a number of attempts to overcome these problems including using gutter guards and other protective screening devices. These types of devices may succeed to a certain extent in preventing large debris from entering a gutter channel, however, they fail to prevent particulate matter from entering the channel so even when using gutter guards and similar devices, one must still clean the gutter channel at regular intervals. [0005] Homeowners often talk of the difficulty in accessing the channel of a gutter for cleaning or for general maintenance. In conventional gutter systems, one is forced to either climb a ladder or mount the roof itself in order to clean the gutter channel and downpipes. This is not only difficult, but may also be dangerous and often results in the homeowner having to pay a specialist to complete the task on their behalf. There exist some prior art gutter systems which include means to pivot the gutter for easier access thereto, however, there are a number of problems associated with these apparatus. [0006] Most existing pivotable systems involve the use of quite complex mechanisms for actuating pivot of the gutter. Those skilled in the art would know that the more parts involved in a gutter system, the more expensive the system is to manufacture and the more difficult the system is to operate. This also ultimately results in greater cost to the consumer. Further, complex componentry of a gutter system is much more susceptible to damage due to rain and wind as opposed to systems having simple mechanical parts and a smaller number of parts. [0007] The installation of known pivotable gutter systems, whether it is a newly installed system or a system adapted to be retrofitted into an existing non-pivotable gutter system, is problematic and cumbersome. The problem arises from the need to direct water away from the gutter. In some systems known to the applicant, the downpipes, which traditionally extend downwards from a lower surface of the gutter channel, must be redesigned to allow for the pivotable movement of the gutter. The design and positioning of such downpipes is often inadequate in that they do not allow for the quick and easy retrieval of water away from the gutter channel. [0008] Further, those skilled in the art would realise that in redesigning and manufacturing new downpipes, the complexity and cost of such systems also increases. Also, retrofitting such gutter systems onto existing gutter arrangements is not really an option in that if the downpipes have to be replaced, then the entire existing gutter will typically need to be removed as well. There is therefore a requirement for a pivotable gutter system to be able to accommodate for existing conventional downpipe arrangements. In the case of newly installed systems, this will eliminate the need for designing and manufacturing new types of downpipes, and in the case of retrofitted systems, this will simplify installation in that only minor manipulation of the existing gutter arrangement is required and desired aesthetic appearance may be maintained. [0009] Some pivotable gutter systems require that the gutter be specially designed and contoured to the design of the gutter system. It would be preferable to have a pivotable gutter system whereby any form or cross-section of gutter may be fixed thereto. [0010] There is therefore a need for a simple, low cost, easily produced pivotable gutter system which retains the integrity of a conventional rain gutter system. [0011] It is therefore an object of the present invention to overcome at least some of the aforementioned problems or to provide the public with a useful alternative. SUMMARY OF THE INVENTION [0012] Therefore in one form of the invention there is proposed a gutter system including: [0000] a longitudinal gutter; at least two support brackets spaced apart along said longitudinal gutter for supporting the gutter below a roof edge, whereby each of said at least two support brackets includes a mounting member adapted to be fixedly mounted to a surface below the roof edge, and a pivotable member having said gutter attached thereto, said pivotable member being pivotably moveable between a first position wherein said gutter is positioned to receive liquid, to a second position wherein said gutter is easily accessible from a position therebelow. [0013] The present invention therefore provides for a pivotable gutter system whereby the gutter is pivotably moveable between a first position for receiving rainwater or other liquid to a second pivoted position to facilitate cleaning or any other duties which need to be performed thereto. One can also appreciate that the present invention overcomes the problems associated with prior art gutter systems in its simple yet effective configuration. [0014] Preferably said mounting member includes two perpendicular edges, a side edge for mounting to said surface and a top edge adapted to extend outwards from said surface over said gutter. [0015] Preferably said pivotable member includes two perpendicular edges, a bottom edge which extends outwards from said surface and beneath said gutter and a side edge to which said gutter is attached. [0016] In preference the bottom edge of the pivotable member is pivotably connected to the side edge of the mounting member whilst the side edge of the pivotable member is lockable to the top edge of the mounting member. [0017] Advantageously said lock is in the form of a latch. [0018] Preferably said pivotable member first position constitutes said pivotable member being locked to said mounting member whilst said pivotable member second position constitutes said pivotable member being unlocked from said mounting member and in a fully pivoted position. [0019] Preferably movement of said pivotable member from said first position to said second position involves a rotation of approximately 90 degrees. [0020] Preferably said gutter includes at least one open portion adapted to permit the exit of liquid from said gutter. [0021] In preference said at least one open portion of the gutter is located at an end thereof. [0022] Preferably said at least one open portion may be located at any point along said gutter. This may be the case where the aesthetic nature of the gutter is important, for example, at the front of a home where it is preferable for downpipes and open portions to not be visible. [0023] Preferably said gutter system includes at least one downpipe including at least one inlet of a sufficient size to allow liquid from one or more gutter open portions to be received therein. [0024] Preferably said downpipe inlet is located a pre-determined distance below said at least one gutter open portion thereby allowing liquid from said gutter to be received therein. [0025] Preferably said pre-determined distance between the at least one gutter open portion and the downpipe inlet is sufficient to allow for said pivotable member to be rotated to said second position. [0026] In preference when said pivotable member is in said second position, said at least one gutter open portion remains above the corresponding downpipe inlet so that liquid may continue to be received therein. [0027] Advantageously, said at least one downpipe includes a straining means for preventing foreign particles from entering said downpipe. [0028] Advantageously each of said brackets of said gutter system are affiliated with one another in such a way that when a pivotable member of one bracket is unlocked from a corresponding mounting member, the pivotable members of the remaining brackets are also unlocked from each of their corresponding mounting members. This is beneficial in that one does not need to unlock each and every bracket in order to pivot the gutter but simply one bracket which automatically unlocks the remaining brackets. This may be achieved by mechanical means or even motorised means. [0029] In a further form of the invention there is proposed a gutter system of the type adapted to be mounted beneath a longitudinal roof edge, said gutter system including: [0000] a plurality of brackets mounted at spaced apart longitudinal intervals below said roof edge whereby each of said brackets includes a mounting member and a gutter carrying member pivotably connected thereto and pivotably moveable between a first and a second position; a longitudinal gutter including two opposed open ends, said gutter adapted to be carried within the gutter carrying members of each of said spaced apart brackets such that when the gutter carrying members are in said first position, the gutter is adapted to receive liquid from thereabove, and when the gutter carrying members are in the second position, the gutter is pivoted for easier access thereto; and at least one downpipe located a predetermined distance below said gutter open ends for receiving liquid therefrom, said pre-determined distance being sufficient to allow for pivot of the gutter carrying member into said second position. [0030] In a preferred embodiment of the invention there is proposed a gutter system including: [0000] at least a first gutter section; at least a second gutter section, said second gutter section being moveable between a first position wherein at least one water receiving surface of said first and second gutter sections are axially aligned, and a second position whereby said water receiving surfaces are misaligned such that said second gutter section is more easily accessible from a position therebelow. [0031] In preference said first gutter section is adapted to be fixedly mounted to a surface below a roof edge and said second gutter section is pivotably mounted to said surface. [0032] Preferably said gutter system includes a sealing means adapted to seal the gap between the first and second gutter sections to thereby integrate the respective water receiving surfaces when the second gutter section is in the first position. [0033] Advantageously said first gutter section includes at least one means of transporting water away from the gutter system. [0034] Preferably said water transporting means is in the form of a downpipe. [0035] The present invention according to a second embodiment therefore provides for an improved gutter system in that the gutter system includes sections that are moveable from a first position for receiving rainwater or other liquid to a second pivoted position to facilitate cleaning or any other duties that need to be performed thereto. The gutter system further includes sections that are fixed so that conventional gutter systems having conventional downpipe configurations need not be altered significantly to include such pivotable gutter sections. [0036] Preferably said gutter system includes at least two spaced apart brackets, each of said brackets including a mounting member, and a gutter carrying member pivotably connected thereto, said gutter carrying members adapted to support said second gutter section. [0037] In preference said sealing means is in the form of a sealing material lining at least the inner side of the gutter carrying member. [0038] Advantageously said sealing means is in the form of a sealing material lining the inner side of the mounting member and the gutter carrying member. [0039] Preferably a bracket is mounted adjacent each end of the second gutter such that when the second gutter section is in said first position, the sealing material lining the inner side of the bracket provides a seal at the junction between respective first and second gutter sections. [0040] Preferably said mounting member includes two perpendicular edges, a side edge for mounting to said surface and a top edge which extends over said gutter, said top edge including a recess for allowing space for said roof edge. [0041] Preferably said pivotable member is contoured to the cross-sectional shape of the gutter. [0042] In preference said second gutter section is lockable in said first position. [0043] Advantageously said lock is in the form of a latch. [0044] Preferably movement of said pivotable member from said first position to said second position involves a rotation of approximately 90 degrees. [0045] In a further embodiment of the invention there is provided a gutter system including: [0000] at least a first gutter section; at least a second gutter section, said second gutter section being pivotably moveable between a first position wherein at least one water receiving surface of said first and second gutter sections are axially aligned, and a second position whereby said water receiving surfaces are misaligned such that said second gutter section is more easily accessible from a position therebelow, said first gutter section including a sealing means adapted to seal the gap between the first and second gutter sections when said second gutter section is in said first position. [0046] In this situation, the brackets no longer require a sealing means and may be positioned in from the edge of the second gutter section. This may be done for aesthetic reasons for example. [0047] In preference said sealing means is a sealing material lining the inner surface of an end of the first gutter, said sealing material extending longitudinally beyond the end so that when the second gutter section is in said first position, the sealing material seals the gap between the first and second gutter sections to thereby form a single water receiving surface. [0048] In preference said second gutter section is lockable in said first position. [0049] Advantageously said lock is in the form of a latch. [0050] Preferably movement of said pivotable member from said first position to said second position involves a rotation of approximately 90 degrees. BRIEF DESCRIPTION OF THE DRAWINGS [0051] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several implementations of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the drawings: [0052] FIG. 1 illustrates a perspective view of a gutter system according to a first embodiment of the present invention, including a gutter in a first position for receiving rainwater from a roof edge; [0053] FIG. 2 illustrates a perspective view of the gutter system of FIG. 1 whereby the gutter is in a second pivoted position; [0054] FIG. 3 illustrates a cross-sectional view of the gutter system as shown in FIG. 1 ; [0055] FIG. 4 illustrates a cross-sectional view of the gutter system as shown in FIG. 2 ; [0056] FIG. 5 illustrates a perspective view of the gutter system of FIGS. 1-4 including a downpipe positioned beneath a roof edge external corner for receiving water from the gutter ends; [0057] FIG. 6 illustrates a perspective view of the gutter system and associated downpipe of FIG. 5 whereby the gutter is in the second pivoted position; [0058] FIG. 7 illustrates a perspective view of the gutter system of FIGS. 1-4 including a downpipe positioned beneath a roof edge re-entrant corner for receiving water from the gutter ends; [0059] FIG. 8 illustrates a perspective view of an alternate style of gutter system for mounting at the front of a house in accordance with the first embodiment of the present invention; [0060] FIG. 9 illustrates a perspective view of a gutter system according to a second embodiment of the present invention, including pivotable gutters in a first position for receiving rainwater from a roof edge in accordance with the present invention; [0061] FIG. 10 illustrates a perspective view of the gutter system of FIG. 9 whereby the pivotable gutters are in a second pivoted position; [0062] FIG. 11 illustrates a cross-sectional view of the gutter system as shown in FIG. 9 ; [0063] FIG. 12 illustrates a cross-sectional view of the gutter system as shown in FIG. 10 ; [0064] FIG. 13 a illustrates a perspective view of a pivotable bracket which forms part of the gutter system of FIGS. 9-12 ; [0065] FIG. 13 b illustrates a side view of the pivotable bracket of FIG. 13 a; [0066] FIG. 14 illustrates a perspective view of a gutter system including pivotable gutter sections in a first position for receiving rainwater from a roof edge in accordance with a third embodiment of the present invention; [0067] FIG. 15 illustrates a cross-sectional view of a pivotable gutter section of FIG. 14 ; [0068] FIG. 16 illustrates a cross-sectional view of a pivotable gutter section of FIG. 14 in a pivoted position for easier access thereto; [0069] FIG. 17 illustrates an enlarged perspective view of the pivotable gutter section as illustrated in FIG. 15 ; and [0070] FIG. 18 illustrates an enlarged perspective view of the pivotable gutter section as illustrated in FIG. 16 . DESCRIPTION OF THE PREFERRED EMBODIMENTS [0071] The following detailed description of the invention refers to the accompanying drawings. Although the description includes exemplary embodiments, other embodiments are possible, and changes may be made to the embodiments described without departing from the spirit and scope of the invention. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts. [0072] The present invention relates to a pivotable gutter system according to three separate embodiments. The first embodiment relates to pivotable gutter system 10 illustrated in FIGS. 1-8 , the second embodiment relates to pivotable gutter system 100 illustrated in FIGS. 9-13 b , and the third embodiment relates to pivotable gutter system 150 illustrated in FIGS. 14-18 . These are each described in turn below. [0073] The pivotable gutter system 10 according to a first embodiment of the invention includes a series of brackets 12 that are adapted to be longitudinally spaced apart along a fascia 14 or other similar surface that lies underneath and extends along the length of a roof 16 . The fascia 14 caps the ends of a plurality of roof rafters 15 . The roof 16 in this example is of the corrugated iron type having an end cap 18 separating each face however the system 10 of the present invention may be applied to any style of roofing, for example tiled roofing. [0074] Each bracket 12 includes two members, a mounting member 20 that is fixedly attached to the fascia 14 and a pivotable member 22 that is in pivotable connection with the mounting member 20 . Unlike conventional gutter systems having gutters that are mounted directly to the fascia 14 or other surface, the present invention involves a gutter 24 being mounted to the pivotable members 22 of each bracket 12 such that the gutter 24 is effectively supported by each spaced apart bracket 12 . Those skilled in the art should immediately realise the simplicity and effectiveness of the gutter system 10 in that the pivotable members 22 of each bracket 12 together with the gutter 24 are pivotable from a standard water receiving position (as shown in FIGS. 1 and 3 ) to a pivoted position to facilitate cleaning and maintenance thereof (as shown in FIGS. 2 and 4 ). Each of these components and their working will now be described in greater detail. [0075] Mounting members 20 and pivotable members 22 are each substantially L-shaped, rigid structures, that is, they each include two edges that are angled substantially perpendicularly to one another. As is illustrated in the accompanying drawings, a side edge of mounting member 20 is fastened to the fascia 14 using screws 26 , this edge having a closed loop section 28 at its end, whilst its top edge extends over the top of the gutter 24 and includes a latch 30 in the form of a turned section. Pivotable member 22 has a base edge that also terminates into a closed loop section 32 which engages with loop section 28 of mounting member 20 to thereby allow for pivot of the pivotable member 22 relative to the mounting member 20 . A side edge of gutter 24 is mounted to the side edge of the pivotable member 22 using rivets 34 , this member 22 also having a bent or turned section 36 that is adapted to be easily connected and disconnected from latch 30 . [0076] When the brackets 12 and gutter 24 are positioned as shown in FIGS. 1 and 3 , rainwater that falls onto the pitched roof 16 runs down into the gutter 24 in the same way it would when using a conventional gutter system. Obviously, the fact that the gutter is capable of being pivoted means that conventional downpipe arrangements cannot be used. For this reason, the ends 38 of each gutter 24 are open to thereby cause liquid that is collected within the gutter 24 to run off the gutter ends 38 . The method of collection of this liquid shall be later described. [0077] FIGS. 2 and 4 illustrate the gutter system 10 when the turned section 36 of member 22 of each bracket 12 has been disengaged from their respective latches 30 and the gutter 24 is pivoted. The pivoted position of the gutter 24 allows for the inside of the gutter to be very quickly and easily cleaned and generally allows for easy access to the inside of the gutter for any other purpose that may be required such as maintenance and repair. [0078] It is to be understood that the methods of connection as described above may well vary. For example, bracket 12 may be mounted to fascia 14 using some form of adhesive (not shown) that is capable of fixing the mounting member 20 and supporting the remainder of the apparatus including the weight of any debris that may enter the gutter. Rather than using rivets 34 to attach the gutter 24 to the pivotable member 22 of the bracket 12 , the gutter may well be constructed integrally with the pivotable member 22 . [0079] Insofar as rotation of the pivotable member 22 is concerned, the use of rounded sections 28 and 32 which are pivotably engaged is by way of example only and any other suitable means of pivoting member 22 may be used, as will become apparent in the final embodiment. For example, the bracket may be motorised so that when a user pushes a button, an electrical impulse trigger actuation of the pivotable member 22 from its standard position to its pivoted position, or vice versa. [0080] Further, bracket 12 need not be limited to the form illustrated and described. For example, rather than members 20 and 22 being thin pieces of metal that are spaced at intervals along the length of the gutter 24 , bracket 12 may be made to extend a greater longitudinal distance of the gutter, perhaps in the form of an extruded bracket having a fixed longitudinal member and a pivotable longitudinal member. [0081] In using the gutter system 10 as described thus far, one needs to unlock each and every bracket 12 in order to commence pivoting the gutter 24 for easier access thereto. This may prove timely and therefore the gutter system 10 according to a first embodiment of the present invention may well include a linking means (not shown) that links each pivotable member 22 such that when a member 22 of a single bracket 12 is unlocked from latch 30 , the members 22 of the remaining brackets along the length of the gutter 24 are simultaneously unlocked from their respective latches 30 . Those skilled in the art would realise that a system having such features would require a user to simply climb a ladder (not shown), unclip a single bracket 12 which disengages the remainder of the brackets 12 , and proceed to pivot the gutter 24 for whatever purpose is required. [0082] Due to the simplicity of the brackets 12 , one may connect just about any form of gutter thereto. The drawings illustrate a gutter 24 of stepped-down cross-sectional size to that of the cross-section of the brackets 12 however it is to be understood that the gutter 24 need not be of this exact cross-sectional shape and may vary. The skilled addressee would understand that the gutter system 10 is preferably adapted for the building of new homes however due to its adaptability, the gutter system 10 may well be retrofitted into existing homes and other structures. For example, one simply needs to dismantle an existing gutter from a fascia or other surface and install the new system 10 . If the existing gutters of the home are requested by the homeowner to be used due to their aesthetic nature for example, the existing gutter may simply be incorporated into the gutter system 10 . [0083] As previously mentioned, the water from the gutter system 10 must still be somehow transported away from the house. This is achieved quite easily using the various downpipes 40 of the gutter system 10 as illustrated in FIGS. 5 to 8 . [0084] As those skilled in the art would no doubt be aware, homes and other like structures generally have corners that either project outwardly (external corners) as shown in FIGS. 5 and 6 , or corners that are joined inwardly (re-entrant corners) as shown in FIG. 7 . The gutter system 10 is capable of accommodating for either configuration. [0085] Rather than the downpipes being connected to the gutter 24 itself, they are spaced a pre-determined distance below the gutter ends 38 for collection of rainwater therein. As can be seen, the openings of the downpipes 40 are considerably large in comparison to conventional downpipes of this sort. The assembler must be sure to position the downpipes low enough to ensure that the gutter 24 has enough space there below to allow for it to be pivoted. One can thus appreciate that when the gutter 24 is in its standard rainfall receiving position, rain will simply run off the gutter ends 38 into the downpipes 40 located there below. When the gutter is pivoted and say for example a hose is used to spray within the gutter under pressure, this liquid is also made to run off the ends 38 of the gutter 24 into the downpipes 40 . The downpipes 40 also include strainers 42 for preventing larger particles from entering. The strainers 42 are slightly angled so as to cause water to travel along the strainer surface and into the strainer apertures, preventing water build-up. The strainers 42 are also surrounded by a wall 44 around the periphery of the downpipe openings which as can be seen are partially opened. The walls 44 are partially opened so that debris that collects on the strainers 42 may be easily removed. [0086] For aesthetic purposes, a user may not wish for the gutter system 10 to be viewable from the front of a home. FIG. 8 illustrates a system which works in the same way as hereinbefore described, however, includes gutter 46 which faces the front of a home. Rather than the end of the gutter 46 being open, an opening 48 exists in the side wall of the gutter 46 adjacent the end wall 50 so that water may travel into the downpipe out of sight of the front of the house. Further, the downpipe 40 may be positioned further on the side of the house rather then at the corner. In fact, the gutter system 10 may vary such that open portions of the gutter may be located at any position along the gutter depending on the requirements of the user. [0087] Those skilled in the art should therefore now realise the benefits of using the gutter system 10 according to a first embodiment of the present invention. The gutter system 10 provides a simple and effective means of accessing a gutter 24 for cleaning and general maintenance without affecting the integrity of the gutter 24 as is often compromised in existing pivotable gutter systems. [0088] As mentioned in the preamble of the invention, it is often a requirement for existing gutter systems to be kept and for the pivotable system to be retrofitted thereto. For example, when one wishes to maintain the aesthetic nature of an existing gutter arrangement, the gutter system 10 is not really appropriate because it requires the installation of newly designed and manufactured downpipes. Gutter systems 100 and 150 according to a second and third embodiment of the present invention respectively, provide a means to overcome this problem and are described in detail below. [0089] Referring firstly to FIGS. 9-12 which illustrate the gutter system 100 according to a second embodiment of the present invention, it can be seen that the gutter system 100 is divided into fixed gutter sections 112 and pivotable gutter sections 114 which are located adjacent one other and configured to allow for the pivot of sections 114 . The gutter sections 112 and 114 have substantially identical cross-sections so that when the sections are aligned, an almost continuous gutter channel between the sections is formed. The fixed sections 112 are generally located at the end portions of the gutter system, for example, at the corners of a roof. However, certain circumstances may require a fixed section 112 to be located at other positions along the perimeter of the roof 116 and so the present invention is not to be limited to any particular portion of the perimeter. Existing gutter systems typically include downpipes 118 in the form of pipes of circular cross-section which extend downwards from the gutter channel typically at the ends or corners of gutters. [0090] As with the first embodiment, the gutter systems 100 and 150 are also preferably adapted to be mounted to a roof fascia 120 which caps the ends of a plurality of roof rafters 122 . Again, the roof 116 in this example is of the corrugated iron type supported on a plurality of purlins 123 and having end caps 124 separating each face. [0091] Located at the ends of each pivotable section 114 are brackets 126 which are each mounted to the fascia 120 or other similar surface which lies underneath and extends the length of the roof 116 . The brackets 126 each include two primary members, a mounting member or end plate 128 that is fixedly attached to the fascia 120 , and a pivotable member or supporting base 130 to which an end of the pivotable gutter section 114 is mounted. The pivotable member 130 is in pivotable connection with the mounting member 128 by way of a hinge 132 . Each bracket 126 is positioned so that adjoining gutter sections 112 and 114 are supported by resting on top of the base, i.e. the bracket straddles under the gutter sections. When the pivotable gutter section 114 is in the first water receiving position as shown in FIGS. 9 and 11 , the bracket 126 covers any gap between the sections 112 and 114 . It is to be understood that some roof edges may be of a larger length whereby further brackets (not shown) may be required along the length of the gutter section 14 for further support and to assist in the pivoting motion of the gutter section 114 . [0092] As with the first embodiment, those skilled in the art should immediately realise the simplicity and effectiveness of the gutter system 100 in that the pivotable gutter sections 114 are pivotable from a standard water receiving position (as shown in FIGS. 9 and 11 ) to a pivoted position to facilitate cleaning and maintenance thereof (as shown in FIGS. 10 and 12 ), whilst still being able to use known arrangements for directing water away from the gutter system 100 , in this case being the downpipes 118 . [0093] The bracket 126 may be seen most clearly in FIGS. 13 a and 13 b . Mounting member 128 comprises a vertical section 134 for mounting to a surface, a recessed section 136 extending outwardly therefrom designed to allow for various extensions of the roof 116 , and a locking lip 138 extending outwardly from a substantially upwardly extending end of the member 128 . As mentioned, the pivotable member 130 is of a shape to accommodate D-gutters and is thus contoured accordingly. A rounded termination 140 of the pivotable member 130 includes an aperture 142 adapted to engage the locking lip 138 by simply lifting the pivotable member 130 until the aperture 140 is able to pass over lip 138 . The present invention is not intended to be limited to this type of connection means, however, if this connection means is to be used, the bracket 126 should be of a flexibility to allow for the movement of the pivotable member 130 to engage the lip 138 . [0094] The bracket also includes a sealing means 141 in the form of a foam seal which extends along the inner side of the vertical section 132 of the mounting member 128 and along the inner side of the pivotable member 130 up to but not including the rounded termination 140 . As those skilled in the art would realise, when the bracket is engaged and the gutter is in the water receiving position, the foam seal 142 extends along the gap between gutter sections 112 and 114 to thereby keep water from leaking out through the gap. This is the reason that the bracket extends a short distance past the ends of the pivotable gutter sections 114 as mentioned earlier, so as to accommodate for the end of the fixed section 112 and to thereby achieve an effective seal. [0095] As is further illustrated in the accompanying drawings, vertical side 134 of the mounting member 128 is fastened to the fascia 120 using screws 144 which may either be screwed over the top of the sealing means 141 or underneath the sealing means 141 . The end of the pivotable gutter section 114 is mounted to the outer edge of the pivotable member 130 of the bracket 126 using rivets 146 . [0096] When the brackets 126 and associated pivotable gutter sections 114 are positioned as shown in FIGS. 9 and 11 , rainwater that falls onto the pitched roof 116 runs down into the gutter section 114 in the same way it does in gutter section 112 . Because a seal between the gutter sections 112 and 114 exists, water is able to flow from the pivotable section 114 to the fixed section 112 as would be the case in a conventional gutter system. [0097] FIGS. 10 and 12 illustrate the gutter system 100 when the pivotable members 130 of each bracket 126 has been disengaged from the mounting members 128 and the pivotable gutter sections 114 thus in a pivoted position. When the gutter section 114 is in this position, it allows for the inside of the gutter to be very quickly and easily cleaned and generally allows for easy access to the inside of the gutter section for any other purpose that may be required, such as for maintenance and repair. [0098] The skilled addressee would understand that the gutter system 100 according to a second embodiment of the invention is preferably adapted for the building of new homes, however due to its adaptability, may well be retrofitted into existing homes and other structures. For example, one simply needs to cut out a section of the gutter that is required to be pivotable, fasten the brackets to the appropriate area, and then simply mount the gutter section that has been cut out between the brackets. This is useful in that installation of the new system becomes cheaper because of the use of the existing gutter and downpipes, and also to preserve the original visual appearance of the home. [0099] Furthermore, in the case of newly installed systems, manufacturing equipment used to make gutter system components such as gutter channels and downpipes, need only be reconfigured slightly to incorporate the new features of the gutter system 100 . There is no longer the need to redesign and manufacture a new downpipe arrangement as the gutter system 100 incorporates existing downpipe arrangements as part of the system. [0100] Due to the simplicity of the brackets 126 one may connect just about any form of gutter thereto by simply selecting the contour of the bracket pivotable member 130 to match the contour of the gutter. Alternatively, rather than the gutter sections 112 and 114 being of stepped-down cross-sectional size to that of the cross-section of the brackets 126 , as is illustrated, they may simply be of a size to accommodate various types of gutter cross-section. [0101] It is to be further understood that pivoting of the gutter section 114 need not necessarily be achieved by manually disengaging the connection means and moving it. For example, the bracket 126 may well be mechanised, or may incorporate the use of activating solenoids. [0102] As with the first embodiment, the gutter system 100 may well include a linking means (not shown) that links the pivotable member 130 of opposed brackets 126 such that when the rounded termination 140 of pivotable member 130 of a single bracket 126 is lifted above lip 138 for disengagement therefrom, the pivotable member 130 of the opposed bracket 126 is simultaneously unlocked from its respective lip 138 . [0103] It is to be understood that the methods of connection as described above may well vary also. For example, bracket 126 may be mounted to fascia 120 using a form of adhesive (not shown) that is capable of fixing the mounting member 128 and supporting the remainder of the apparatus including the weight of any debris that may enter the gutter section 114 . Rather than using rivets 146 to attach the gutter section 114 to the pivotable member 130 of the bracket 126 , the pivotable member 130 may well be constructed integrally with the gutter section. [0104] FIGS. 14-18 illustrate a third and final embodiment of the present invention, gutter system 150 , which also includes fixed 152 and pivotable 154 gutter sections. Some features of the gutter system 100 that have not been altered are referred to in the following description of the third embodiment using like numbers. [0105] In the gutter system 100 , the brackets 126 performed two functions. They not only allowed the pivotable gutter section 114 to pivot, they also provided a seal between the sections 112 and 114 . In this embodiment, brackets 156 are not positioned at the ends of the pivotable sections 154 but are shifted inwards. This is because they no longer provide the seal required between sections 152 and 154 , but simply provide for the pivoting motion of the pivotable gutter sections 154 . The sealing of the gap between sections 152 and 154 is achieved through the relationship between the ends of sections 152 and 154 which will later be explained. [0106] The brackets 156 each include a mounting member 158 , and a pivotable member 160 in the form of a rectangular plate in pivotable connection with the mounting member 158 through hinge 162 . As can be seen clearly in FIGS. 15 and 16 , the pivotable member 130 of the previous bracket 126 is replaced by the pivotable gutter section 154 itself. The inner vertical side 164 of the pivotable gutter section 154 is connected to each plate 160 through rivets 166 . The engagement means of bracket 156 is virtually identical to that of bracket 126 . The only difference resides in the fact that locking lip 168 of mounting member 158 extends through an aperture 170 in a buckle 172 which is connected to the rounded edge of the gutter section 154 by a rivet 174 . [0107] Referring now to FIGS. 17 and 18 , the way in which sections 152 and 154 are sealed can be appreciated. The end of the fixed gutter section 152 now includes an internal sealing member 175 which is contoured to the inside of the fixed gutter section 152 and extends longitudinally outwards therefrom. Approximately half the length of the sealing member 175 is fixed within the section 152 by rivets 176 whilst the other half extends outwards. Located uniformly around the outer surface of the sealing member is a sealing sponge 178 or other suitable sealing means. During assembly, the ends of the pivotable gutter sections 154 are adapted to be positioned adjacent the ends of the fixed sections 152 such that when in a first water receiving position, the sealing member 175 also extends into the end of the pivotable section 154 thus providing a substantially horizontal surface upon which water is able to flow. [0108] In this configuration, since the use of a simple rivet will not provide an adequate seal, water that may travel underneath the sealing member 175 as opposed to over it, is soaked up by the sealing sponge 178 thereby effectively sealing the gap between sections 152 and 154 . Pivotable gutter section 154 also includes a cut-out 180 so that it is able to pivot as required. [0109] As those skilled in the art would understand, it is not essential for bracket 156 to be positioned at the very ends of the pivotable gutter sections 154 but in order to ensure that an effective seal is achieved, it is preferable for the brackets 156 to be positioned as close to the ends as possible. [0110] This third embodiment allows for the pivotable motion of the gutter section 154 and an effective seal between fixed 152 and pivotable 154 gutter sections, without the visibility of a pivoting bracket member, thereby improving the overall aesthetic nature of the gutter system 150 . A further benefit is that during installation of such gutter systems 150 , one no longer has to secure the brackets 156 at precise positions along the fascia 120 . [0111] A proposed solution to making cleaning of gutters easier is through the use of a gutter guard or gutter protection device. None of these prior art devices are known to prevent all particulate matter, including miniscule particles, from entering a gutter and therefore regular cleaning of the gutter is always required. In simply using a gutter guard, the intervals at which the gutter is cleaned may be prolonged but nonetheless, the gutter must still be cleaned which necessitates a quick and easy method of accessing the gutter. The pivotable nature of the gutter system of each embodiment of the present invention solves this known problem. [0112] Those skilled in the art should therefore now realise the benefits of using the gutter systems embodying the present invention. The proposed gutter systems provide a simple yet effective means of accessing a gutter by way of pivoting only a section of the gutter for cleaning and general maintenance, with the option of retrofitting the gutter system so that existing downpipe arrangements are not substantially interfered with. The gutter systems 10 , 100 and 150 of the present invention thus serve to maintain the integrity of conventional gutter systems which is often compromised in pivotable gutter systems hitherto known. [0113] The components of the gutter systems 10 , 100 and 150 disclosed herein are preferably constructed substantially of aluminium due to its corrosion resistance, or any other suitable metal having similar properties or which at least may be coated with a water and/or wind resistant coating (not shown) such as a zinc-based coating, for example. Alternatively, these components may be constructed of a suitable plastic material. [0114] Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope and spirit of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus.
Pivotable gutter having brackets spaced apart comprising mounting members ( 20 ) and carrying member ( 22 ). The gutter being lockable ( 30, 36 ) in a first position. The gutter has open ends sections ( 112, 114 ) that is sealable via sealing means ( 141 ) or a lining ( 178 ) with other gutter sections when the gutter sections are in the first position.
4
PRIORITY AND RELATED APPLICATION [0001] N/A FIELD OF THE INVENTION [0002] The present invention relates to x-ray imaging, in particular, to alignment systems for portable x-ray imaging devices. BACKGROUND OF THE INVENTION [0003] In a hospital setting, mobile radiographic exams are performed on patients that are incapable of being moved, or are difficult to move. In tertiary care medical centers, mobile radiographic exams represent a significant percentage of the radiographic exams performed. X-rays passing through an object, such as a human body, experience some degree of scatter. The primary x-rays transmitted through an object travel on a straight line path from the x-ray source (also referred to herein as the x-ray focal spot) to the image receptor and carry object density information. Scattered x-rays form a diffuse image that degrades primary x-ray image contrast. In some patients, scattered x-ray intensity exceeds the intensity of primary x-rays. Scattering phenomena is well known and routinely compensated for in general radiography, fluoroscopy and mammography through the use of anti-scatter grids. [0004] An anti-scatter grid is generally formed from alternating strips of x-ray opaque (or radiopaque) material and x-ray transmissive (or radiolucent) material. Lead may be used as the x-ray opaque material and plastics, aluminum or fiber may be used as the x-ray transmissive material. The grid is positioned between the object of interest and the x-ray image receptor plate and oriented such that the image forming primary x-rays are incident only with the edges of the x-ray opaque material. Thus, the majority of primary x-rays pass through the radiolucent spacer strips. In contrast, scattered x-rays are emitted in all directions after interaction with the target object and as such, scattered x-rays are incident on a larger area of the lead strips and only a small percentage of scattered x-rays are transmitted by the grid, as compared to primary x-rays. [0005] The degree of scatter control for a given grid depends upon the grid ratio, which is defined as the ratio of the radiopaque strip thickness in the direction of the x-ray path to the width of the radiolucent spacer material as measured orthogonal to the x-ray beam path. Thus, the higher the grid ratio, the greater the scatter control. A high grid ratio, while more effective, is also more difficult to align relative to a focal spot. In order to compensate for x-ray beam divergence in a focused grid, the radiopaque strips are tilted to a greater extent with increasing distance from the center of the grid. The planes of the grid vanes all converge along a line known as the focal line. The distance from the focal line to the surface of the grid is referred to as the focal length of the grid. The focal line coincides with the straight line path to the focal spot. Thus, when the focal spot is coincident with the focal line of the grid, the primary x-rays have minimal interaction with the radiopaque lead strips and maximal primary transmission is obtained. Misalignment of the focal line of the anti-scatter grid with the focal spot diminishes primary x-ray transmission while scattered x-ray transmission remains unchanged. Thus, optimal primary x-ray transmission requires alignment (positional and orientational) of the focal spot with the focal line of the anti-scatter grid. [0006] In general radiography, fluoroscopy and mammography, the image receptor and x-ray tube are rigidly mounted and in a fixed position relative to one another, thereby making focal spot and grid alignment a simple process. In mobile radiography, an image receptor is placed under a bedridden patient and the x-ray source is positioned above the patient. Since the relative separation of the focal spot and the image receptor is variable, determining the proper position and orientation of an anti-scatter grid between a patient and the image receptor becomes a difficult alignment problem. If a grid is not used, only a small fraction of the possible contrast is obtained in the x-ray image. [0007] When grids are utilized in conjunction with mobile radiography, the grid is typically not aligned. Misalignment problems are diminished by utilizing a grid having a low ratio of 8:1 or less. Although x-ray image contrast is improved with the use of a low ratio grid, the contrast remains significantly lower than otherwise could be obtained with a properly aligned, high ratio grid having a grid ratio of 10:1 or greater. [0008] Thus while mobile radiography is in many ways more convenient than fixed installation radiography, its clinical utility is diminished due to the inferior image quality caused by scattered radiation. This is a greater problem in mobile radiography due to the difficulty in producing the proper alignment of the focal spot with the anti-scattering grids. A means to produce proper alignment that is easy for the operator to use would significantly improve mobile radiographic image contrast and image quality, and thus increase the clinical utility of mobile radiography. SUMMARY OF THE INVENTION [0009] A system and method for determining the location of an x-ray source of an x-ray machine and for adjusting grid lines in an anti-scatter grid are disclosed. In one embodiment, the invention uses a source locator in conjunction with an infrared (IR) transmitter and IR receiver to locate the x-ray source and to align grid lines with an ideal x-ray beam path. By aligning the grid lines with the beam path, images with increased contrast and reduced noise can be produced. [0010] The present invention provides a system for determining location of an x-ray source of an x-ray machine such as a portable x-ray machine. The system includes an x-ray source and a source locator. The x-ray source emits x-ray beams which have an idealized beam path. The source locator is associated with the x-ray source and has an IR transmitter. The IR transmitter of the source locator transmits location information defining the location of the x-ray source with the location information being generated by the source locator. The system may further comprise an x-ray grid having an IR receiver and x-ray grid lines that adjust to the emitted x-ray beams. The grid lines selectively permit the emitted x-ray beams to pass through said x-ray grid and align with the idealized path of the emitted x-ray beams. The grid lines adjust to the idealized beam path and selectively permit the emitted x-ray beams to pass through the x-ray grid in response to the IR emissions received by the IR receiver. [0011] The present invention also provides a system for obtaining x-ray images with increased contrast and reduced noise. The system includes an x-ray beam source and an adjustable x-ray grid. The x-ray beam source emits x-ray beams and has a source locator associated therewith for determining the location of the x-ray source. The x-ray grid includes a plurality of grid lines comprising alternating radiopaque and radiolucent material. The grid lines of the x-ray grid may be adjusted to said x-ray beam source using an electromagnetic field, a servo motor or other computer driven mechanisms. The grid lines may be adjusted between a first unobstructed position that permits x-ray beam emissions to pass through the grid, and a second obstructed position that prohibits x-ray beam emissions from passing through the grid. The grid lines may comprise strips of material or individual radiolucent spheres with radiopaque material disposed in a central plane of each radiolucent sphere. The radiolucent material has a first charged side and a second charged side, where said first charged side is an opposite charge from said second charged side. [0012] The present invention further provides a method of adjusting grid lines in an anti-scatter grid by providing an x-ray source, providing an adjustable x-ray grid and adjusting said x-ray grid lines to align with x-ray beam emissions of said x-ray source. In one embodiment radiolucent spheres include a layer of radiopaque material disposed in a central plane of each sphere. The adjustment means selectively align said x-ray grid lines to permit passage of said x-ray beam emissions through said x-ray grid. The adjustment means also includes use of a computer that receives location information obtained by the source locator to selectively align said x-ray grid lines to an idealized path of said x-ray beam emissions and to permit passage of said x-ray beam emissions through said x-ray grid. BRIEF DESCRIPTION OF THE DRAWINGS [0013] FIG. 1 is an illustration of a portable x-ray apparatus according to the present invention. [0014] FIGS. 2A and 2D are illustrations of a source locator disposed on an x-ray source of the portable x-ray apparatus according to FIG. 1 . [0015] FIG. 3 is an embodiment of an x-ray plate employed in FIG. 1 . [0016] FIG. 4 is another embodiment of an x-ray plate employed in FIG. 1 . [0017] FIGS. 5A-5C illustrate the use of radiolucent spheres as embodiments of an x-ray grid. DETAILED DESCRIPTION OF THE INVENTION [0018] FIGS. 1 and 3 show a system 100 of the present invention for aligning x-ray emissions from an x-ray machine and for adjusting grid lines in an anti-scatter grid to obtain diagnostic image information with increased contrast and reduced noise due to scattered x-rays. The system 100 includes a portable x-ray machine 110 having an x-ray head 115 and an x-ray plate 150 used to removably receive an x-ray film cassette or digital x-ray detector 155 . In one embodiment, a source locator 120 is attached to the housing of x-ray head 115 of x-ray machine 110 and x-ray plate 150 is attached to a flexible filter, anti-scatter grid 160 . Both the source locator 120 and the flexible filter, anti-scatter grid 160 are mechanisms used to facilitate the acquisition of images with increased contrast and reduced noise when compared to images obtained using prior art portable x-ray machines and prior art grids. [0019] Referring now to FIG. 2A , there is shown a source locator 120 in greater detail. The purpose of source locator 120 is to determine the location of the x-ray source 200 , and to record that location information in an appropriate digital storage device. The digital storage device is then associated with circuitry affixed to x-ray head 115 so that once the source locator is removed, or the x-ray head itself is moved, the location of the x-ray source in a particular x-ray head is stored and accurately known at all times. [0020] Shown in FIG. 2A is x-ray source 200 , the location of which must be determined, x-ray opaque object 201 and an image 202 of the x-ray opaque recorded on film 203 . As described below, determination of the size differences between object 201 and image 202 , along with appropriate computer calculations based on these differences, allow a precise determination of the x-ray source location. When the mobile x-ray machine is turned on x-ray radiation 204 is generated which passes over object 201 and is recorded on film 203 as image 202 . As object 201 is x-ray opaque, the size of image 202 will vary based on the relative locations of x-ray source 200 , object 201 and image 202 . [0021] Referring now to FIG. 2B , there is shown the manner in which the location of the x-ray source can be calculated. More particularly, the location coordinates of Points A and C are known as the “Y” dimension (distance 205 ) is known and fixed. Similarly distance 207 is known, so that the locations of Points B and D are known but distance 206 is variable and not known. Using known techniques, the difference in size between object 201 and image 202 can be readily determined. [0022] Knowing the location of Points D and C it is possible to calculate the relative angle of line 208 and knowing that angle it is possible to calculate the correct angle of line 209 . The extension of lines 208 and 209 can be calculated to determine the precise location of x-ray source 200 . It is to be understood that the known calculations described above would be accomplished on a computing device (not shown) associated with source locator 120 . FIG. 2C illustrates the use of a star-shaped object 201 , which represents an example of a figure with more distinct visual landmarks than the disc 201 shown in FIG. 2B , which may be employed to simplify the needed calculations. [0023] FIG. 2D shows an example where the x-ray is off center but the same process described above can be used to calculate its precise location. FIG. 2D also illustrates a representation of the digital storage device 210 described above in which the location information for x-ray source 200 is stored. [0024] Referring specifically to FIG. 3 , the source locator 120 is disposed on, integrated with or removably attachable to the x-ray head 115 of the x-ray machine 110 . The locator 120 is used to determine the location of the actual x-ray focal spot 200 of the portable x-ray machine 110 as described above. The source locator 120 has, for example, infra red (IR) transmitters 130 disposed thereon and x-ray plate 150 has, for example an IR receiver 140 disposed thereon. The IR transmissions from transmitter 130 are received by IR receiver 140 in order to transmit the location of the x-ray source 200 . It is understood that the location of the x-ray source 200 is stored in digital device 210 , which stored information is used by IR transmitter 130 . The general concept of using an IR transmitter and an IR receiver to transmit the location of a particular object is known. See for example U.S. Pat. No. 5,627,524. This system or similar known techniques can be used in accordance with the present invention. [0025] After the location of x-ray source 200 has been determined and grid 160 adjusted as described below, source locator 120 can be removed from x-ray head 115 . However the location of x-ray source 200 remains stored in digital storage device 210 so that the location of source 200 is available for subsequent use of the portable x-ray machine. [0026] Referring now to FIG. 4 , an embodiment of the x-ray plate 150 is shown. In one embodiment, the flexible filter, anti-scatter grid 160 is attached to the x-ray plate 150 that is used to removably receive detector 155 . In other embodiments, the grid 160 may be removably attached to the x-ray plate 150 . In use, the x-ray plate 150 would be oriented so that a patient would be situated on top of the grid 160 of the plate 150 with the detector 155 being disposed therebelow. The grid 160 reduces the effect of scattering by preventing scattered x-rays from reaching the detector 155 . [0027] The detector 155 may include an x-ray photosensitive film or a digital x-ray detector. For example, a suitable digital detector may include a cesium iodide phosphor (scintillator) on an amorphous silicon transistor-photodiode array having a pixel pitch of about 100 micrometers. Other suitable detectors may include a charge-coupled device (CCD) or a direct digital detector which converts x-rays directly to digital signals. While the photosensitive film is illustrated as being flat and defining a flat image plane, other configurations of the photosensitive film and digital detectors may be suitably employed, e.g., a curved-shaped photosensitive film or digital detector having a curved image plane. [0028] Still referring to FIG. 4 , the grid 160 has adjustable and dynamic grid lines 162 that are adjusted in response to the location of the x-ray focal spot as determined by source locator 112 . This creates an idealized beam path of the x-ray emissions from the x-ray source 200 . The grid 160 communicates with the source locator 120 via the IR transmitters and receivers described above in order to determine the idealized path of x-ray beams and then, based on the idealized path, the grid lines 162 adjust to line up with the idealized path. The grid lines 162 comprise a set of individual strips of radiopaque material and a set of individual strips of radiolucent material as described above. [0029] In one embodiment, the radio-opaque material of the grid lines 162 comprise parallel lead louvers that employ servo motors to adjust the lead louvers based on the calculated idealized path. In this embodiment, a computer system may be used to obtain the idealized path information from the source locator, calculate the location of the focal spot and then adjust the louvers using the servo motor. [0030] FIG. 5A shows another embodiment of x-ray plate 150 that comprises a grid 260 formed of grid lines taking the form of spheres 262 floating in a fluid matrix. The grid 260 would be part of a fluid system where the spheres 262 exist in one plane, or planar system. The spheres 262 may be suspended in any type of fluid or semi-fluid radiolucent material 270 . Each sphere 262 has a plane of radio-opaque material 275 disposed therein. For instance, each sphere 262 has a thin layer of lead or similar radio-opaque material 275 that cuts through the sphere 262 in the center plane 275 . Each sphere 262 would have the same polarity so that each center plane of each sphere 262 would align in response to the application of an appropriate electromagnetic field. When the idealized x-ray path is determined, as described above the control computer would apply an electromagnetic field to the planar system of the grid 260 so the lead plane 275 of the each sphere 262 aligns to the idealized path emitted from the x-ray source 200 . By using an electromagnetic field, the spheres 262 are selectively adjusted to obstruct or permit x-ray beam emissions from the x-ray source 200 . FIG. 5B illustrates one specific alignment of spheres 262 and FIG. 5C illustrates a sphere 262 having more than one plane, specifically two planes in this case, which may increase the performance of the anti scatter grid. [0031] While the present invention has been described in conjunction with specific embodiments, those of normal skill in the art will appreciate the modifications and variations can be made without departing from the scope and the spirit of the present invention. Such modifications and variations are envisioned to be within the scope of the appended claims.
A system and method for determining the location of an x-ray source of an x-ray machine and adjusting grid lines in an anti-scatter grid are disclosed. An ideal beam path is obtained and is used to adjust grid lines in the anti-scatter grid. In one embodiment, the invention uses a source locator to locate the x-ray source, communicate this location to the said adjustable anti-scatter grid which could align the grid lines mechanically, by means of servos attached to the grid lines, to the ideal x-ray beam path. In other embodiment electrical currents are used to align grid lines with the beam source. By aligning the grid lines with the beam path, images with increased contrast and reduced noise can be produced.
0
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] Not applicable. BACKGROUND OF THE INVENTION [0002] 1. The Field of the Invention [0003] The invention relates to accessories for use with a portable device. [0004] 2. The Relevant Technology [0005] The following prior art documents are acknowledged: DE 202004018840, U.S. Pat. No. 5,995,082, U.S. Pat. No. 5,575,578, U.S. Pat. No. 6,353,530, and U.S. 2005/098689. SUMMARY OF THE INVENTION [0006] In its broadest independent aspect, the invention provides an accessory for use with a portable device with a top and bottom surface comprising a platform for facilitating the use of a mouse; and a jaw incorporating an upper and lower portion forming, in use, a gap to receive the side of a portable device; wherein said upper and lower portions are configured to respectively engage, in use, the top and bottom surfaces of said portable device; whereby said jaw releasably secures said accessory to said portable device. This configuration is particularly advantageous because it improves the manner in which the accessory is attached. It provides a particularly stable attachment to the side of a laptop. It also allows fitting to a wide variety of different laptops. [0007] In a subsidiary aspect, said jaw incorporates cushioning pads on said upper and lower portions. This allows the accessory to attach without unduly scratching the top and bottom surfaces of a laptop computer. It also allows improved retention of the accessory during use. [0008] In a further subsidiary aspect, said upper portion and said lower portion are spaced in a substantially parallel relationship in order to facilitate sliding over the top and bottom surfaces of said portable device. [0009] In a further subsidiary aspect, said accessory further comprises a bias between said upper and lower portion to tend to draw said upper portion and said lower portion together; whereby said jaw forms a clip for clipping onto, in use, the top and bottom surfaces of said portable device. This allows the accessory to be fitted to a wide variety of portable devices of varying thicknesses. It also improves the level of security of the fitment. [0010] In a further subsidiary aspect, said platform is a continuation of said upper portion. This configuration provides for a particular stable platform which would be less prone to bending and/or breakage. [0011] In a further subsidiary aspect, a downwardly projecting wall is provided between said platform and said lower portion; and a bracket extends between said wall and said platform. This configuration improves the level of retention of the shape throughout various cycles of use. [0012] In a further subsidiary aspect, said platform includes a mouse mat. [0013] In a further subsidiary aspect, said platform incorporates a raised portion extending upwards from said platform onto which, in use, a user's wrist rests. This improves the level of comfort as well as distributing the load in order to improve the stress distribution. [0014] In a further subsidiary aspect, said accessory incorporates a platform portion and at least one jaw portion which is separable from said platform portion. This configuration allows one or more jaw portions to be used and these to be separately replaced if necessary. [0015] In a further subsidiary aspect, said accessory incorporates two distinctive jaws, and a space between the two jaws; wherein at least one jaw is displaceable; whereby the space between the two jaws may be varied. This allows the accessory to fit onto a wide variety of different portable devices. [0016] In a further subsidiary aspect, at least one of said upper and lower portions is displaceable; whereby the gap between the upper and lower portions may be varied. [0017] In a further subsidiary aspect, said platform incorporates a plurality of recesses and at least one jaw portion incorporates a tongue corresponding to at least one of said recesses. This configuration further improves the characteristic of adaptability of the accessory for fitting most if not all laptop sizes and/or similar devices. BRIEF DESCRIPTION OF THE DRAWINGS [0018] Various embodiments of the present invention will now be discussed with reference to the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. [0019] FIG. 1 shows a perspective view of an accessory in accordance with a first embodiment of the invention. [0020] FIG. 2 shows a side elevation of the first embodiment of the invention. [0021] FIG. 3 shows a perspective view of the underside of the first accessory. [0022] FIG. 4 shows the accessory of FIGS. 1 , 2 , 3 when mounted on the side of a laptop. [0023] FIG. 5 shows a perspective view of the accessory of the preceding Figures with the user's mouse and hand. [0024] FIG. 6A shows a perspective view of a jaw in accordance with a second embodiment of the invention. [0025] FIG. 6B shows the process of assembly of the jaw in accordance with the second embodiment of the invention. [0026] FIG. 6C shows in magnified view the jaw portion engaging side of the body of the jaw. [0027] FIG. 6D shows in magnified view the side of the body of the jaw in accordance with the second embodiment of the invention. [0028] FIG. 7A shows the process of fitting the block in accordance with the second embodiment of the invention. [0029] FIG. 7B shows in cross-sectional view the process of fitting the screw to the block. [0030] FIG. 7C shows in cross-sectional view and in side elevation the assembly of the upper portion to the body of the jaw. [0031] FIG. 8 shows in perspective exploded view the various components forming the accessory. [0032] FIG. 9 shows in perspective view the assembled components of the accessory of the second embodiment of the invention. [0033] FIG. 10 shows in perspective exploded view the various components forming the accessory in accordance with a further embodiment of the invention. [0034] FIG. 11 shows in perspective exploded view the various components forming the accessory in accordance with a further embodiment of the invention. [0035] FIG. 12 shows in perspective exploded view the components forming the accessory in accordance with a further embodiment of the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0036] FIG. 1 shows an accessory generally referenced 1 with a platform 2 facilitating the use of a computer mouse. The accessory is shaped and configured to removably attach to a laptop computer, personal digital assistant (PDA), palmtop and/or any portable device with which a mouse may be used. The platform incorporates an upper layer of the kind suitable for the effective operation of a mouse. The upper layer 3 is preferably of resilient polymeric material. It may be formed of a relatively high friction portion lining on a foam polymeric layer or a gel. The mouse mat which is thus formed rests on a relatively rigid support plate 4 . The support plate 4 projects beyond the mouse mat in a sideways direction to form the upper portion 5 of a jaw generally referenced 6 . The jaw 6 also incorporates a lower portion 7 . Jaw portion 5 and jaw portion 7 are separated by a gap 8 sized and shaped for the insertion of the portable device of the kind described above. As part of the platform 2 a further sideways extending portion is provided as reference 9 in FIG. 3 . On projection 9 , there is provided a wrist rest 10 which may be formed of cushioning material. The wrist rest projection 9 is offset from axis X. This offset is configured to enhance the ergonomic properties of the accessory. [0037] The platform support plate may be relatively rigid compared to the mouse mat. The structure may preferably be of a suitable metal such as aluminum or a relatively rigid polymeric material. The support plate for the jaw portions 5 and 7 may be made of a single piece of material or two or more pieces. As shown in FIG. 3 pads 11 and 12 are provided. These pads may be relatively resilient compared to the support portions 5 and 7 . In a preferred configuration, the pads may be classified generally as non-scratch pads. These may also be of rubber or other similarly resilient material such as felt. The thickness of pads may be varied dependent upon the desired gap size. The lower jaw portion 7 joins the upper jaw portion via a substantially upright wall portion 13 . A radius 14 is provided between wall portion 13 and lower jaw portion 7 . A web/bracket 15 extends between wall portion 13 and platform support 4 in order to assist in maintaining the overall geometry of the accessory. FIG. 3 shows two such webs 15 and 16 . These ensure stability and strength of portion 7 in terms of downward movement and/or of portion 13 in terms of sideways movement. [0038] A step 17 is provided between the platform support 4 and the upper jaw portion 5 so that the width of the jaw is reduced relative to the width of the platform. This reduction in width allows the jaw to rest against the upper and lower surfaces of a portable device such as a laptop 18 as shown in FIG. 4 . [0039] In FIG. 4 , the accessory is sized and shaped to attach sideways onto the laptop 18 . Step 17 is shaped and configured to avoid any overlap with the keyboard. Whilst the jaw portions 5 and 7 are substantially parallel in this embodiment, the invention also envisages jaw portions which progressively narrow from wall portion 13 towards their distal extremities respectively referenced 19 and 20 . The embodiment of FIG. 4 shows the accessory being able to slide into its position where it is retained primarily by friction onto the upper and lower faces of the laptop 18 . In this embodiment, the accessory is retained without any interlock. [0040] The platform 2 as can be seen in FIG. 5 is of sufficient size to accommodate a mouse 21 which could be separately plugged into the laptop. Alternatively, the mouse may wirelessly communicate with the laptop. [0041] Whilst the embodiments of FIGS. 1 to 5 show an accessory where the jaw portions are integral with the platform and are adjustable either in as much as the inherent material properties allows the accessory to be adjusted or by the addition of protective pads, the embodiment presented in the following Figures shows an accessory where the jaw portions are displaceable in at least two dimensions. FIG. 6 shows a jaw generally referenced 22 which when assembled incorporates a lower jaw portion 23 and an upper jaw portion 24 . Each jaw portion incorporates a rounded top surface such as top surface 25 and a relatively flat lap top engaging surface such as surface 26 . Jaw portion 24 is configured to displace in the Y direction in order to adjust the gap size allowing the accessory to fit a range of laptop thicknesses. Jaw portion 23 projects from body 27 . [0042] Body 27 incorporates a cavity chamber 28 into which a block 29 as shown in FIG. 7A can fit. A cavity shaft 30 guides the boss 31 in order to locate the block for motion in the Y direction. Boss 31 has an internally threaded portion 32 in order to receive screw 33 as shown in FIG. 6B and FIG. 7B . Screw 33 is hidden inside a cavity 34 and passes through hole 35 in order to engage the threaded portion 32 of block 29 . The engaged configuration is shown in FIG. 7C . The front face 36 of jaw portion 24 incorporates an array of ridges for co-operation with corresponding ridges located on face 37 as shown in FIG. 6B and in further detail in FIG. 6C . As an alternative to the ridges, the invention envisages employing a high friction pad or a further array of corresponding projections and recesses. In order to distribute the pressure exerted by the screw on the jaw portion 24 a washer 38 is provided between the screw and the inner surface 39 which surrounds the hole 35 . In use, by loosening the screw by employing a screwdriver, body 27 and jaw portion 24 are sufficiently spaced to allow the jaw portion's position to be adjusted by sliding in the Y direction. [0043] Body 27 incorporates a tongue 40 . A trough 41 separates the main portion of the body 27 from the tongue 40 . This upper portion of the body is shaped and configured to fit recesses such as recess 42 provided in the platform 43 (see FIG. 8 ). Each recess takes the form of a tunnel corresponding in size to the tongue 40 and facilitates sliding engagement with the tongue. A guide 44 locates extremity 45 in FIG. 6A as the jaw is inserted into one of the recesses. The recesses are substantially parallel with one another and allow the position of the jaws to be varied in the X direction. [0044] A number of upwardly projecting members such as member 45 are provided at regular intervals on the platform 43 . These projections correspond to recesses located in a frame member 47 such as mat frame 46 and wrist rest 49 . The frames are designed to surround a mouse mat 48 and a wrist rest 49 . The wrist rest 49 fits into the hollow portion 56 provided in the platform. The wrist rest incorporates a projection 57 for fitting into a slot 58 of the frame 47 . A second projection 54 is provided to extend laterally into a further slot 55 provided in frame 47 . A relatively rigid shell 50 is provided to one side of the wrist rest. Whilst the array of projecting members are envisaged to secure the respective frames, further securing mechanisms are envisaged such as filamentary hook and eye pads, and projections located on the frames corresponding to recesses provided in the platform. A lip 51 slides into a slot 52 of the mat frame in order to secure the frame and line it up in order to allow the projections and recesses to fit together. [0045] The assembled accessory is shown in FIG. 9 . The previous embodiments have been shown for securing on the right hand side of a laptop or other portable device, the invention envisages similar embodiments configured to fit the left hand side of a laptop or portable device. [0046] Further embodiments are envisaged where a bias or spring is provided between the upper and lower portions of a jaw in order to form a sprung clip type mechanism which may be used to clip the platform to the side of a laptop. [0047] Instead of envisaging that the upper jaw portion on its own displaces relative to the lower portion, it is envisaged that the lower portion may instead of or as well as the portion displace in order to allow the adjustment of the gap between the portions. [0048] FIG. 10 shows a pad 60 incorporating a substantially flat upper surface on which the mouse would be located in use. A wrist rest 61 extends to one side of the mouse mat. The mouse mat 60 is secured to a plate 62 which in turn is secured to a further support plate 63 . The attachment between plate 62 and support 63 is such as to allow an attachment where the jaws extend either in a right hand direction or in a left hand direction. Arrow 64 indicates the versatility of the support 63 . The figure shows support 63 in either of the two positions. [0049] FIG. 11 shows a mouse mat 65 similar to the mouse mat 60 in FIG. 10 . A support plate is located beneath the mouse mat which incorporates a cylindrical recess 67 . Instead of a recess a projection 67 may be envisaged. Recess 67 is sized and shaped to engage with a projection 68 extending from the support 69 . This embodiment shows how the mouse receiving platform may be rotatable relative to a support in order to allow the accessory to be used on the left hand or the right hand of an accessory. [0050] FIG. 12 shows a mouse mat platform 70 which may be secured to a support 71 . The support plate has arrays of jaw portion receiving means on both sides of the support 71 . These are respectively referenced 72 and 73 . The invention also envisages only having an array on either of these sides so that the accessory may be either for left handers or right handers. [0051] The present invention may be embodied in other specific forms without departing from its spirit or essential 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.
An accessory for use with a portable device with a top and bottom surface includes a platform for facilitating the use of a mouse; and a jaw incorporating an upper and a lower portion forming, in use, a gap to receive the side of a portable device; wherein the upper and lower portions are configured to respectively engage, in use, the top and bottom surfaces of said portable device; whereby the jaw releasable secures the accessory to said portable device.
6
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. provisional application No. 62/294,567 entitled “Auto Logging Detonator,” filed Feb. 12, 2016, the contents of which are incorporated herein by reference. FIELD OF INVENTION [0002] The present invention relates generally to electronic detonators and more particularly, but without limitation, to devices and methods for logging electronic detonators. BRIEF DESCRIPTION OF THE DRAWINGS [0003] FIG. 1 is a schematic illustration of an electronic detonator constructed in accordance with a first preferred embodiment of the present invention. In this embodiment, the auto-logging module is integrated into the detonator's control circuit. [0004] FIG. 2 is field connection diagram for a blast system comprising a plurality of electronic detonators each with an internal auto-logging module as illustrated in FIG. 1 . [0005] FIG. 3 is a schematic illustration of an insulation displacement connector (“IDC”) customized for use in the blast system of the present invention. [0006] FIG. 4 is a schematic illustration of the IDC shown in FIG. 3 with the blast wires, logging wires, blast lines, and logging line all connected. [0007] FIG. 5 shows a functioning block diagram showing the basic operation of a blasting system comprising a plurality of detonators each with an internal auto-logging module as illustrated in FIG. 1 . [0008] FIG. 6 is a functional flow diagram illustrating the auto-logging logic carried out by the control module of auto-logging detonator show in FIG. 1 . [0009] FIG. 7 is a functional flow diagram illustrating the auto-logging logic carried out by the blast machine in a blasting system employing the auto-logging detonator show in FIG. 1 . [0010] FIG. 8 is a schematic illustration of an electronic detonator assembly constructed in accordance with a second preferred embodiment of the present invention. The electronic detonator assembly comprises a conventional electronic detonator electrically coupled to an external detonator logging unit. [0011] FIG. 8A is an enlarged schematic illustration of the detonator logging unit 400 shown in FIG. 8 . [0012] FIG. 9 is field connection diagram for a blast system comprising a plurality of electronic detonator and logging unit assemblies illustrated in FIG. 8 . [0013] FIG. 10 shows a functioning block diagram showing the basic operation of a blasting system comprising a plurality of electronic detonator and logging unit assemblies as illustrated in FIG. 9 . [0014] FIG. 11 is field connection diagram for a blast system comprising multiple rows of electronic detonator assemblies shown in FIG. 8 and further comprising row-to-row row logging units. [0015] FIG. 12 shows a functioning block diagram showing the basic operation of a blasting system comprising a plurality of electronic detonator assemblies and row logging units as illustrated in FIG. 11 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0016] Electronic delay detonators are excellent initiation systems for controlled blasting especially in mining operations. Advantages of electronic detonators are precise timing resulting in reduced vibrations, improved protection from stray electrical currents and radio frequencies and, to an extent, reduction in misfires through precise circuit testing. Many types of electronic detonators are commercially available. Each manufacturer has different modes of operation for each model, which result in the similar functioning on the field. [0017] Irrespective of the various designs and modes of operations of the electronic detonators in the market today, certain procedures usually are carried out while executing a blast operation. Individual detonators are tested, and the boreholes are charged. All the detonators are logged, and the identity of each detonator and its position in the blast pattern is recorded. The blast machine uses this identity to communicate with individual detonators to test, transfer delay data, and to fire the detonators. [0018] The typical blast procedure also includes setting the delay time of each individual detonator according to the blast design. The delay time is transferred or programmed into the detonator either during the logging operation or by the blast machine during the blast procedure. [0019] All the detonators are connected to the main line, and the line testing is conducted to confirm that all detonators are detected in the circuit. This is done by addressing each individual detonator using its specific identity. [0020] In all cases, logging of the detonators on the field is mandatory to record the identity of each of the detonators with the blast hole. This is carried out either by physically connecting the detonator to the logging machine or by scanning the printed code on the detonator using an optical scanner. [0021] The logging is done on the charged holes while the operator stands on it. This is a safety hazard, especially when the logging is done using a physical connection of the detonator; this is because the detonator is powered, even though a safe voltage is being used for logging. In the case of the optical scanning system, a connected logging will be required if the label on the detonator is damaged. Regardless of the method of identification that is employed, all current systems require an operator to physically visit each blast hole and perform some operation in order to carry out the procedure. This process is time consuming and inconvenient and often requires additional personnel in the field. [0022] The present invention is directed to an electronic detonator with an auto-logging component that is either integrated in the circuitry of the detonator or in an external unit that is coupled to the detonator. The remote and automated logging process of this invention is carried out by communications between the blast machine and the detonators and eliminates the manual logging operation on the field. [0023] The present invention includes detonator-to-detonator or “D2D” communication in addition to the conventional blast machine-to-detonator communications. The D2D communication is carried out on a logging line or cable that interconnects the detonators in sequence or series all in a logging circuit with the blast machine. Whether the blast system utilizes electronic detonators with internal auto-logging circuits or an external auto-logging unit, the basic operation is similar. As used herein, “logging circuit” refers to the interconnected components that are involved in the auto-logging operation and includes the blast machine, the detonators, and the logging line by which the blast machine communicates with the detonators. In the context of the present invention, where external auto-logging modules are utilized, the detonator logging units and the row logging units form a part of the logging circuit. While the auto-logging circuit and the blast control circuit have common components, the communication lines may be separate and independent. [0024] The logging line that interconnects the detonators in series is in addition to the conventional two-wire blast lines, also called a bus line, that interconnect the detonators with the blast machine in a blast control circuit for execution of the blast program. As used herein, “blast control circuit” refers to the interconnected components of the blast operation and includes the blast machine, the detonators, and the data and communications lines by which the blast machine communicates with the detonators. In the context of the present invention, where external auto-logging modules are utilized, the auto-logging modules form a part of the blast control circuit. [0025] The present invention also provides a specially designed insulation displacement connector (“IDC”) for use when coupling the detonators to the three-wire bus line. The specialized IDC simplifies the serial or sequential connection of the electronic detonators in the logging circuit while also assuring secure connection to the blast lines as well. Essentially, this connector performs a serialized connection while appearing similar to connectors that perform a parallel connection. [0026] The present invention provides a blasting system in which automated remote electronic logging replaces the on-the-field logging of the detonators. This increases the safety of the on-field personnel also reduces the time required for the overall set up process. These and other features and advantages will become apparent from the following description with reference to the accompanying drawings. [0027] Turning now to the drawings in general and to FIG. 1 in particular, there is shown therein an electronic detonator made in accordance with a first embodiment of the present invention and designated generally by the reference number 10 . The exemplary detonator 10 comprises a hollow tubular shell 12 with a blind or closed end 14 and an opposite open end 16 . An explosive charge is contained in the blind end 14 of the shell 12 . The explosive charge may include a base charge 20 and a primary explosive 22 . [0028] The detonator 10 includes a control module 26 . The control module 26 may be a microcontroller or programmable logic device and more preferably comprises an application-specific integrated circuit chip (ASIC). The control module 26 is programmed to communicate with the blast machine and carry out a plurality of operations including a firing operation in a known manner. In accordance with the present invention, the control module 26 further includes an auto-logging function or module that may be integrated into the control module. The control module 26 is operatively connected to an igniter of any suitable type to initiate the detonation of the explosive charge. In the exemplary detonator shown in FIG. 1 , the igniter is a fuse head 28 . [0029] First and second leg wires 32 a , 32 b have internal ends 34 a , 34 b connected to the control module 26 and external ends 36 a , 36 b outside of the shell 12 for connection to the blast control circuit, described hereafter. Logging wires 38 a , 38 b having internal ends 40 a , 40 b operatively connected to the control module 26 and external ends 42 a , 42 b outside of the shell 12 for connecting the control module to the logging circuit also described below. An end plug or sealing plug 44 may be crimped in the open end 16 of the shell 12 . [0030] Referring now to FIG. 2 , therein is shown an illustrative blast system 50 using a plurality of electronic detonators like the detonator 10 interconnected with a blast machine 52 by a three-wire bus line 54 . The bus line 54 comprises first and second blast lines 56 a and 56 b and a single logging line 60 . While four detonators 10 a , 10 b , 10 c , and 10 d are shown, the blast system 50 may include a larger or smaller number of detonators. The detonators 10 a , 10 b , 10 c , and 10 d are connected to the first and second blast lines 56 a , 56 b by the leg wires 32 a , 32 b to form the blast control circuit 62 . The logging wires 38 a , 38 b of the detonators 10 a , 10 b , 10 c , and 10 d also are connected to the logging line 60 to form the logging circuit 66 . [0031] Notably, as illustrated in the exemplary blasting system 50 , the detonators 10 a , 10 b , 10 c , and 10 d are connected in a series in the logging circuit 66 , as indicated by the numbers 1, 2, 3, and 4, while the detonators are connected in parallel pattern in the blast control circuit 62 . The parallel arrangement of the detonators in the blast control circuit 62 is exemplary only; various other patterns (serial, parallel, etc.) and combinations of such patterns may be employed, as is commonly understood by those skilled in the art. [0032] The leg wires 32 a , 32 b and the logging wires 38 a , 38 b of the detonators 10 a , 10 b , 10 c , and 10 d may be connected to the blast lines 56 a , 56 b , and the logging line 60 of the bus line 54 in any known manner. However, the present invention comprises a specially configured insulation displacement connector (IDC) 68 a , 68 b , 68 c , 68 d , one for each detonator 10 a , 10 b , 10 c , and 10 d. [0033] A preferred embodiment of the inventive IDC will be described with reference to FIGS. 3 and 4 . As the IDC's may be identically formed, only the IDC 68 a will be described in detail. The IDC 68 a comprises an enclosure or casing 70 . Though not shown in detail, the casing 70 preferably will be formed of non-conductive material and most preferably will be waterproof. The casing 70 may include a cover, not shown, that is openable to access the connection structures inside. [0034] The IDC 68 a includes conductive elements configured to pierce the protective sheath on the various wires in order to establish an electrically conductive connection between the wires. To that end, the IDC 68 a includes a first barb set 72 in the casing 70 for electrically connecting the first blast line 56 a of the blast control circuit 62 ( FIG. 2 ) with the first leg wire 32 a of the detonator 10 . A second barb set 74 is structured to electrically connect the second blast line 56 b with the second leg wire 32 b of the detonator 10 . The first and second barb sets 72 and 74 are designed to connect the leg wires without severing the blast lines. [0035] Referring still to FIGS. 3 and 4 , the IDC 68 a includes a third barb set 76 in the casing 70 for electrically connecting the logging line 60 of the logging circuit 66 ( FIG. 2 ) to the first logging wire 38 a of the detonator 10 and a fourth a barb set 78 for electrically connecting the logging line to the second logging wire 38 b . As indicated above, in the preferred practice of the invention, the detonators are connected in series in the logging circuit 66 . To sever the logging line 60 , the IDC 68 a includes a line cutter 82 positioned between the third and fourth barb sets 76 and 78 for electrically severing the logging line 60 . The line cutter preferably comprises a pair of blades 82 a and 82 b. [0036] To facilitate the correct placement of the electrical conduits in the IDC 68 a , the casing 70 may include a channel for each conductor. As used here, “channel” denotes any structure that services to position the conductor in the casing. Thus, “channel” includes a groove, recess, snap ring, cradle, or other such structure, and the channel may be a continuous or discontinuous structure. For that reason, the channels are shown only in broken lines and only in FIG. 3 . [0037] A indicated in FIG. 3 , a first bus wire channel 86 is provided in the casing for receiving a section of the first blast line 56 a of the blast control circuit 62 . Also included is second bus wire channel 88 for receiving a section of the second blast line 56 b , and a third bus wire channel 90 for receiving a section of the logging line 60 of the logging circuit 66 . A fourth channel 94 is formed in the casing for receiving a section of the first logging wire 38 a of the detonator, and a fifth channel 96 is included for receiving a section of the second logging wire 38 b . Still further, a sixth channel 98 is configured for receiving a section of the first leg wire 32 a , and a seventh channel 100 is configured for receiving a section of the second leg wire 32 b. [0038] In this way, the interconnection of the leg wires and logging wires on each detonator can be quickly and correctly spliced with the three-line bus wire by placing the respective conductors in the appropriate channel. More importantly, the inventive IDC accomplishes this multi-wire connection while ensuring that the blast lines of the blast control circuit are not interrupted and that that the logging line of the logging circuit is effectively severed. It will be appreciated that the inventive IDC devices may be sold separately or as part of a detonator and connector assembly, as in most instances a connector will be needed for each detonator. [0039] Once the blast system 50 is fully assembled in the field, the detonators 10 a , 10 b , 10 c , and 10 d are logged. As indicated, the blast machine 52 ( FIG. 2 ) and the control module 26 in each detonator are programmed to carry out an automated detonator logging operation that eliminates the need for personnel in the field. In accordance with the invention, the detonator logging operation includes the blast machine transmitting a unique detonator sequence number to each detonator. Each detonator accepts an assigned detonator sequence number from the blast machine in response to logging status from an immediately preceding detonator in the series. Then, the detonator posts a “logged” status flag for output to the immediately succeeding detonator in the series. [0040] The detonator logging operation is summarized in the flow diagram of FIG. 5 . The detonator logging operation commences with the blast machine 52 powering up all the detonators 10 a , 10 b , 10 c , and 10 d , as indicated at block 102 . Next, at block 104 , the blast machine 52 begins the initialization process by transmitting an initialization command on the logging line 60 ( FIG. 2 ). Initially, only the first detonator 10 a will respond to the “initialize” command, and the other detonators 10 b , 10 c , and 10 d will reject the command since they are not enabled. [0041] By means of the D2D communication on the logging circuit, as indicated at block 106 , the blast machine 52 will assign the first detonator 10 a detonator sequence number 1, and the first detonator will confirm acceptance of the detonator sequence number assigned to it. The logged detonator 10 a will then post its status as “logged” for signalling to the next detonator 10 b . The blast machine 52 then repeats the initialization command and sends the detonator sequence number 2 to the second detonator 10 b . Upon confirming the “logged” status of the immediately preceding detonator (in this case detonator 10 a ), the second detonator 10 b accepts the sequence number “2” posts its status now as “logged,” which will then enable the next detonator for initialization. [0042] This process repeats until all detonators in the series have responded. When no further “initialized” signals are received from the logging circuit, the blast machine ends the detonator logging operation. At this point, the blast machine has associated a specific sequence number with each detonator allowing detonator-specific communication to execute other commands as necessary to complete the blast operation. [0043] Turning now to FIG. 6 , the functional logic of the detonator logging operation performed by the control module 26 in the detonator 10 will be explained in more detail. At START 200 , the detonator gets power from the blast machine 52 . All initializing routines are run, and the detonator is ready to receive commands from the blast machine. The detonator sequence number and delay time data stored in the module's memory are reset to zero. [0044] At 202 , the detonator receives data from the blast machine 52 . This data includes the command signal to do specific processes, an assigned detonator sequence number, and the delay time data. At 204 , the detonator verifies whether the command is to commence the detonator logging operation. If the command is for logging, then at 206 the program determines if the assigned sequence number (“detonator #”) in its memory is zero or greater than zero. If the Detonator # is greater than zero or “no,” the detonator is already logged, and the program returns to 202 and for new command. [0045] If, at block 206 , the Detonator # in memory is zero or “yes,” then the program proceeds to block 208 and checks the data flag from the previous detonator, if any, at 216 . If the flag of the preceding detonator is not set, or the response to the query at 208 is “no,” the log command is not for this detonator, and the logic returns to 202 for the next command. If the flag at 216 is set, or the response to the query at 208 is “yes,” then the logging operation proceeds to block 210 , and the detonator stores the received sequence number in its memory along with the updated delay time data. [0046] Next, at block 212 , the detonator will set the data flag output connected to the next detonator in series. This “logged” status will be detected by the next detonator in series when it conducts its logging operation. Finally, after posting its “logged” status data flag, at 214 the detonator replies to the blast machine that the logging process is completed. [0047] At block 204 , if the initial response is “no,” that is, if the command is not for logging, the program proceeds to 218 and checks if the command is to commence the firing operation. If “no,” then the command is for another function, and the program proceeds to perform such other functions 220 as commanded and returns to the “receive data” station at 202 . If at 218 , the command is for firing or “yes,” the program proceeds to block 222 , and again queries the memory for the stored detonator sequence number. If the stored sequence number is zero, the detonator is not logged and the program returns to step 202 for further commands. If the stored sequence number is greater than zero, then the “logged” status is verified, and the program proceeds to execute the fire command at block 224 whereupon the operation is ended at 226 . [0048] With reference now to FIG. 7 , the logic employed by the blast machine 52 in relation to the automatic detonator logging operation will be described. Commencing at START 300 , the blast machine 52 ( FIG. 2 ) is initialized and is ready to function. The blast machine assumes that that all the detonators 10 a , 10 b , 10 c , and 10 d are connected in the logging circuit 66 in series. For example, if the blast pattern has multiple rows, as in subsequent embodiments described below, the machine assumes that the last detonator in the first row is connected to the first detonator in the second row, and so forth. [0049] At 302 , the blast machine receives input from the operator for the blasting operation. This data includes blast pattern, including how many rows of detonators, and how many detonators in each row (“holes per row”). This data also includes delay times for each detonator, including row-to-row delay time values and hole-to-hole delay time values. In particular, the data includes to total number of detonators in the blast pattern designated as “N T .” [0050] At 304 , in response to a LOG Command from the operator, the blast machine switches on the detonator power, and all the connected detonators are powered. The blast machines sends out a LOG command to each detonator in sequence along with the delay time data for that specific detonator. Additionally, before initiating the logging operation, the detonator's assigned sequence number “N S ” and the number of detonators logged “N L ” are reset to zero at block 306 . At block 308 , as the logging operation progresses, the blast machine incrementally increases the detonator sequence number N S as each detonator is logged. [0051] As indicated, N S is the sequence number of the detonator connected in the field. From the blast operation data input at step 302 , the blast machine computes the position of the detonator (row# and hole#) with this sequence number N S . The delay time for that detonator is computed using the delay time data from step 302 . For example, the following formula may be employed: [0000] Delay Time=((row#−1)×row delay)+((hole#−1)×hole delay) [0000] where the row# and hole# start from 1. [0052] At step 312 , the blast machine sends the data to the detonators connected on the field. This data includes the command to log the detonator, the detonator number, and the respective delay time value. At step 314 , this data is received by the respective detonator on the field, and the detonator replies to the blast machine. The blasting machine will not proceed without a reply from the detonator at step 314 . If the response at block 314 is “yes,” the logic returns at 316 to step 308 , whereupon the detonator number N S is ticked up and the operation proceeds to log the next detonator in the sequence. If no reply is received from the detonator at 314 after a predetermined interval of time, this indicates that all detonators have been logged, and the logic moves to step 318 . [0053] At 318 , after receiving no further replies from detonators in the field, the logic then compares the total number of detonators logged “N L ,” with the pre-programmed number of total detonators in the blast operation, N T , which was input at 302 . If N L equals N T , the logic proceeds to step 320 and completes the rest of the blasting program. If N L does not equal N T , the logic displays an error at 322 and returns to START 300 of the operation. [0054] At the completion of the logging operation, all the detonator in the blast operation are logged, each detonator has received and accepted its own unique detonator-specific sequence number. This number can be used by the blast machine to communicate with individual detonators to perform operations like diagnostics or modification of programmed delay time data etc. The remainder of the blast operation is carried out according to conventional procedures. [0055] In the previous embodiment, the control module 26 of the detonator 10 was programmed to include the detonator logging module, as previously described. In some instances, it may be desirable to provide an external or separate detonator logging unit. One preferred embodiment of an external detonator logging unit is shown in FIGS. 8 and 8A , to which we now turn. In FIG. 8 , the detonator logging unit 400 is shown electrically coupled to a conventional electronic detonator 402 forming a detonator-logging assembly 404 comprising an electronic detonator and the detonator logging unit. The exemplary detonator 402 comprises a hollow tubular shell 406 with a blind or closed end 408 and an opposite open end 410 . An explosive charge is contained in the blind end 408 . The explosive charge may include a base charge 412 and a primary explosive 414 . [0056] The detonator 402 includes a control module 416 . The control module 416 may be a microcontroller or programmable logic device and more preferably comprises an application-specific integrated circuit chip (ASIC). The control module 416 is programmed to communicate with the detonator logging unit 400 . The detonator logging unit 400 is equipped with terminals 418 a , 418 b ( FIG. 8A )) to electrically connect to the leg wires 420 a and 420 b . The detonator 402 communicates with the blast machine (not shown in this figure) through the detonator logging unit 400 . The control module 416 is operatively connected to an igniter of any suitable type, such as the fuse head 418 , to initiate the detonation of the explosive charge. [0057] Although separate and self-contained, the detonator logging unit 400 is similar in its functions and programming to the logging operation of the electronic detonator 10 in the previous embodiment. To that end, the detonator logging unit 400 may comprise a logging module 424 contained in a suitable housing 426 . As indicated, the housing 426 includes terminals 418 a , 418 b by which the logging module 424 is operatively connectable to the leg wires 420 a and 420 b of the electronic detonator 402 . [0058] The detonator logging unit 400 may form part of a blast system 428 depicted in FIG. 9 in a manner similar to the previous embodiment. The blast system 428 comprises a blast machine 430 that is connected with a plurality of detonator-logging units 400 a , 400 b , 400 c , and 400 d by a three-wire bus line 432 . The bus line 432 comprises first and second blast lines 434 a and 434 b and a logging line 436 . The blast lines 434 a and 434 b connect the detonator-logging units 400 a , 400 b , 400 c , and 400 d in a blast control circuit 440 , and the logging line 436 connects the detonator-logging units 400 a , 400 b , 400 c , and 400 d in a logging circuit 442 . [0059] As best seen in FIG. 8A , the detonator logging unit 400 comprises first and second logging wires 442 a and 442 b and first and second blast wires 444 a and 444 b . As seen in FIG. 8A , the first and second logging wires 442 a and 442 b have internal ends 446 a , 446 b operatively connected to the logging module 424 . The external ends 448 a and 448 b of the first and second logging wires 442 a and 442 b are outside of the housing 426 for connecting the logging module 424 to the logging module of the detonator logging unit associated with the immediately preceding electronic detonator in the logging circuit 442 ( FIG. 9 ) and the logging module of the of the detonator logging unit associated with the immediately succeeding electronic detonator in the logging circuit, as shown in FIG. 9 . [0060] Referring still to FIG. 8A , the first and second blast wires 444 a and 444 b have internal ends 450 a and 450 b operatively connected to the logging module 424 and external ends 452 a and 452 b outside of the housing 426 for connecting the detonator logging unit to the blast control circuit 440 ( FIG. 9 ). Thus, the detonator logging unit 400 is interposed between the leg wires 420 a and 420 b of the electronic detonator 402 and the blast circuit 440 ( FIG. 9 ). [0061] As indicated, the logging module 424 of the external detonator logging unit 400 is programmed to carry out the same logging operation as previously described in relation to the detonator 10 . However, now it will be appreciated that the external logging unit 400 conveniently may also function as a conventional surface connector. For example, positioned outside the shell as a programmable surface connector the unit 400 may operate as a “Hole to Hole delay” and “Row to Row delay,” as is done in conventional blast design using “Surface delay+DTH” combination. Still further, although not depicted in FIGS. 8 and 9 , the logging units 400 a , 400 b , 400 c , and 400 d may be connected to the bus wire 432 by using the IDC connectors, as previously described. [0062] The detonator logging operation for the blast system 428 ( FIG. 9 ) is summarized in the flow diagram of FIG. 10 . The detonator logging operation commences with the blast machine 430 powering up all the detonator logging units 400 a , 400 b , 400 c , and 400 d , and associated detonators 402 a , 402 b , 402 c , and 402 d , as indicated at block 460 . Next, at block 462 , the blast machine 430 begins in the initialization process by transmitting an initialization command on the logging line 436 ( FIG. 9 ). Initially, only the first detonator logging units 400 a will respond to the “initialize” command, and the other detonator logging units 400 b , 400 c , and 400 d will reject the command since they are not enabled. [0063] By means of the D2D communication on the logging circuit 442 , indicated at block 464 , the blast machine 430 will assign the first detonator-logging unit 400 a detonator sequence number 1, and the first detonator logging unit 400 a will confirm acceptance of the detonator sequence number and assign it to the detonator 402 a connected to it. The logged detonator logging unit 400 a will then post its status as “logged” and will set the data flag output connected to the next detonator-logging unit 400 b . The blast machine 430 then repeats the initialization command and sends the detonator sequence number 2 that will be accepted only by the detonator-logging unit 400 b . The second detonator-logging unit 400 b accepts the sequence number “2” posts its status now as “logged,” which will then enable the next detonator-logging unit for initialization. [0064] This process repeats until all the detonator-logging units 400 a , 400 b , 400 c , and 400 d in the series have responded after initiating the connected detonators 402 a , 402 b , 402 c , and 402 d , respectively. When no further “initialized” signals are received from the logging circuit, the blast machine ends the detonator logging operation. At this point, the blast machine has associated a specific sequence number with each detonator in the system allowing detonator-specific communications to execute other commands as necessary to complete the blast operation. [0065] The previously described blast systems 50 and 428 illustrate examples of blast patterns that comprise a single row of electronic detonators. However, many blast systems comprise detonators arranged in a plurality of rows. An example of such a blast pattern is illustrated in FIG. 11 , to which attention now is directed. [0066] The multi-row blast system, designated generally at 500 , comprises three (3) rows R 1 , R 2 , and R 3 of four (4) detonators each. Each of the detonators is shown as part of a detonator-logging unit comprising a detonator and an external or surface detonator logging unit, as described above in connection with FIGS. 8-10 . It will be understood that a multi-row blast system alternately could employ the detonators with the built-in logging module. The blast system 500 comprises a blast machine 502 interconnected in a blast control circuit 504 by first and second blast lines 506 and 508 and also interconnected in a logging circuit 510 by a logging line 512 . The blast lines 506 and 508 and logging line 512 form a three-wire bus line 516 , as in the previous embodiments. [0067] In accordance with the present invention, the multi-row blast system 500 further comprises a plurality of row logging units 520 a , 520 b , and 520 c , including a row logging unit operatively associated with a different one of each of the plurality of rows R 1 , R 2 , and R 3 . As with the detonator logging units previously described, the row logging units 520 a , 520 b , and 520 c , are interposed in the logging circuit 510 in series by the logging line 512 . The customized IDC connectors previously described may also be used to connect the row logging units 520 a , 520 b , and 520 c to the bus line 516 . The row logging units 520 a , 520 b , and 520 c provide row-to-row (“R2R”) communication similar to the detonator-to-detonator or D2D communication provided by the detonator logging units. [0068] Each of the row logging units 520 a , 520 b , and 520 c may comprise a housing and a row logging module in the housing. As these units are similar to the units 400 of the previous embodiment, they are not shown or described in detail. Each of the row logging units 520 a , 520 b , and 520 c is configured to execute a plurality of operations including a row logging operation. The blast machine 502 and the row logging units 520 a , 520 b , and 520 c carry out a row logging operation that corresponds to the detonator logging operation previously explained. [0069] The row logging operation includes accepting an assigned row sequence number (Row 1.0, Row 2.0, Row 3.0, etc.) from the blast machine 502 in response to row logging status from an immediately preceding row logging unit in the series of row logging units and posting row logging status for output to an immediately succeeding row logging unit in the series. Each of the row logging units 520 a , 520 b , and 520 c is configure to receive and store in its memory row logging data from the blast machine 502 . The row logging data from the blast machine 502 comprises an assigned row number that is zero or a number greater than zero. The row logging operation includes completing the row logging operation if the assigned row number in the memory is zero and ending the row logging operation if the assigned row number is greater than zero. [0070] The row logging operation includes checking for row logging status posted by the immediately preceding row logging unit in the logging circuit and ending the row logging operation if no logging status is detected for the immediately preceding row logging unit. If a “logged” status is detected for the immediately preceding row logging unit, the row logging operation is completed by accepting the assigned row number received from the blast machine, posting a “logged” status for output to an immediately succeeding row logging unit in the logging circuit, and signalling to the blast machine that the row logging operation is completed. Preferably, the blast machine is configured to complete the row logging operation prior to starting the detonator logging operation. [0071] The detonator logging operation for the blast system 500 ( FIG. 11 ) is summarized in the flow diagram of FIG. 12 . The detonator logging operation commences at block 530 with the blast machine 502 powering up all the detonator logging units and associated detonators of the detonator-logging assemblies. Next, at step 532 , the blast machine 502 initializes the row logging or R2R units. Then, at block 534 , the blast machine 502 initializes the detonators, one row at a time, using the D2D detonator logging units. Thus, the blast machine 502 in this embodiment is configured to complete the row logging operation prior to starting the detonator logging operation. [0072] Once all detonator logging units and row logging units have been successfully logged, the blast machine is able to use the unique identifier for unit to communicate with individual logging units and detonators to perform the blasting operation or other functions. It should be noted that the identifier assigned to each detonator indicates which row the detonator is in and what number the detonator is the row. That is, the assigned identifier should contain the row and the hole numbers. For example, the second detonator in the third row will be identified as number 3.2 [0073] Now it will be appreciated that the present invention provides a system and method by which the process of logging detonators in a blast operation is made more safe and more efficient. In addition to the conventional blast control circuit, the system includes a logging circuit. Regardless of the blast pattern of the detonators, the logging circuit connects the detonators in a series. [0074] The first detonator in the series, that is, the detonator connected directly to the blast machine, will identify itself as the first detonator in the circuit and then activate the next detonator in the series. The second detonator, then, turn will tag itself as detonator number two and activate the next in the circuit in a relay-like protocol. In this way, each detonator becomes associated with a unique identifier, which is its sequence number in the blast pattern. The blast machine can then use the unique identifiers to communicate with individual detonators. [0075] The embodiments shown and described above are exemplary. Many details are often found in the art and, therefore, many such details are neither shown nor described herein. It is not claimed that all of the details, parts, elements, or steps described and shown were invented herein. Even though numerous characteristics and advantages of the present invention have been shown in the drawings and described in the accompanying text, the description and drawings are illustrative only. Changes may be made in the details, especially in matters of shape, size, and arrangement of the parts, within the principles of the inventions to the full extent indicated by the broad meaning of the terms of the attached claims. The description and drawings of the specific embodiments herein do not point out what an infringement of this patent would be, but instead provide an example of how to use and make the invention. Likewise, the abstract is neither intended to define the invention, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way. Rather, the limits of the invention and the bounds of the patent protection are measured by and defined in the following claims.
A blasting system with automated detonator logging eliminates on-the-field manual logging of each detonator. Detonators are connected in sequence in an auto-logging circuit, and the blast machine initiates a logging operation in which each detonator receives and confirms an assigned sequence number along with assigned delay data. Elimination of manual logging by individuals increases safety in the blast zone and facilitates the blasting operation. The operation is simplified, likelihood of human error is reduced, and the cost of a separate logger device is eliminated. An auto-logging protocol may be incorporated into the control module of the electronic detonator. Alternately, an auto-logging module may be connected externally to each detonator similar to the conventional surface plus down-the-hole delay systems. The inventive system may include an IDC connector that facilitates the serial connection of the detonators for the logging circuit while allowing parallel connections of the blast control circuit.
5
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to electrical devices comprising conductive polymer compositions. 2. Introduction to the Invention Conductive polymers are well known. They comprise a particulate conductive filler which is dispersed in, or otherwise held together by, an organic polymer. They can be used in circuits in which current passes through them, eg. in heaters and circuit protection devices, and in such use they may exhibit what is known as PTC (positive temperature coefficient) or ZTC (zero temperature coefficient) behavior. The term "PTC behavior" is usually used in the art, and is so used in this specification, to denote a composition which, in the operating temperature range, has an R 14 value of at least 2.5 or an R 100 value of at least 10, preferably both, and which preferably has an R 30 value of at least 6, where R 14 is the ratio of the resistivities at the end and the beginning of the 14° C. temperature range showing the greatest increase in resistivity, R 100 is the ratio of the resistivities at the end and the beginning of the 100° C. temperature range showing the greatest increase in resistivity, and R 30 is the ratio of the resistivities at the end and the beginning of the 30° C. temperature range showing the greatest increase in resistivity. The term "ZTC behavior" is usually used in the art, and is so used in this specification, to denote a composition which does not show PTC behavior in the operating temperature range; thus the term is used to include (a) compositions which show no substantial change in resistivity over the operating temperature range (eg. from room temperature to 100° C.), (b) compositions which show substantial increases in resistivity over the operating temperature range but still do not have R 14 , R 30 or R 100 values as specified above, (c) compositions which show substantial decreases in resistivity over the operating temperature range [often denoted NTC (negative temperature coefficient) compositions], and (d) compositions as defined in (a), (b) and (c) which exhibit PTC behavior at temperatures above the operating temperature range. Documents describing conductive polymer compositions and devices comprising them include U.S. Pat. Nos. 3,861,029, 4,177,376, 4,237,441, 4,315,237, 4,352,083, 4,413,301, 4,426,339, and 4,459,473, the disclosures of which are incorporated herein by reference. SUMMARY OF THE INVENTION The electrodes which have been used to make physical and electrical contact with conductive polymers include solid and stranded wires, metal foils, and expanded and perforated metal sheets. We have now discovered that improved physical and electrical properties can be obtained through the use of electrodes which have a microrough surface which is in direct physical and electrical contact with the conductive polymer. The term "microrough" is used herein to denote a degree of surface irregularity which is different from that observed in stranded wires and perforated metal sheets, and which is sufficient to provide improved physical bonding between the metal and the conductive polymer. Thus in one aspect the present invention provides an electrical device which comprises (1) an element composed of a conductive polymer, and (2) at least one metal electrode having a microrough surface which is in direct physical contact with the conductive polymer element. BRIEF DESCRIPTION OF THE DRAWING The invention is illustrated in the accompanying drawing in which: FIG. 1 is a side view of a device of the invention. DETAILED DESCRIPTION OF THE INVENTION The microrough surface of the electrodes used in the present invention can be prepared in a number of different ways. The preferred method is electrodeposition, the microrough surface being the surface which is exposed to the electrolyte. For example, electrodeposited foils, particularly copper and nickel foils, are preferred for use in this invention. It is also possible to use other processes which result in a similar degree of roughness, eg. irregularities which protrude from the surface by a distance of at least 0.03 microns, preferably at least 0.1 microns, particularly 0.1 to 100 microns, and which have at least one dimension parallel to the surface which is at most 500 microns, preferably at most 100 microns, particularly at most 10 microns, and which is preferably at least 0.03 micron, particularly at least 0.1 micron. The irregularities can be of the same shape as those produced by electrodeposition, eg. generally spherical nodules protruding from the surface, or they can be of a different shape. Such processes can create the microrough surface by removal of material from a smooth surface, eg. by etching, by chemical reaction with a smooth surface, eg. by galvanic deposition, or by deposition of a microrough layer of the same or a different material on a smooth surface. A smooth foil can be treated by contact e.g. rolling or pressing with a patterned surface to generate a microroughness. The microrough surface can if desired be treated to change its chemical characteristics. For example, an electrodeposited metal foil can be passivated i.e. rendered inactive or less chemically reactive, by an appropriate treatment, eg. one which provides a coating thereon of a water-stable oxide, especially a zinc-nickel or nickel treatment of an electrodeposited copper foil. Such treatment is for example desirable where the metal may catalyse degradation of the conductive polymer. Such treatment can also be carried out so as to provide appropriate acid-base interactions with the conductive polymer. Through the use of microrough surfaces on the electrodes, the range of conductive polymers which can be used is increased. For example, when using a conventional mental foil, it is often necessary for the conductive polymer to include a polar copolymer or other polymeric ingredient which provides improved adhesion to the mental foil but whose presence detracts from the desired electrical characteristics. Thus the invention makes it possible to use a wider range of conductive polymers (both PTC and ZTC) in situations in which separation of the electrode and the conductive polymer is an anticipated problem, either as a result of flexing, different coefficients of expansion, exposure to solvents, eg. diesel fuel, or thermal or electrical shock. Suitable conductive polymers are disclosed in the documents incorporated herein by reference. Preferred conductive polymers include those based on polyolefins, particularly high density polyethylene, and those based on fluoropolymers, particularly polyvinylidene fluoride. Advantages of the improved adhesion include the ability to punch very small parts from foil laminates and substantially improved life, even when exposed to high voltages. The invention can be used in any of the devices described in the documents incorporated herein by reference, including in particular circuit protection devices, particularly laminar devices having for example a resistance of less than 100 ohms, particularly less than 25 ohms, especially less than 1 ohm. Very small laminar devices, having at least one laminar dimension which is less than 0.2 inch, eg. less than 0.15 inch, and even smaller, such as less than 0.1 inch, can be prepared by punching a foil laminate. Other useful devices include self-limiting heaters, especially flexible sheet heaters having a total surface area of at least 1.0 square inch. The invention is illustrated by the following Examples. EXAMPLE 1 The ingredients listed in the Table below were tumble-blended, mixed in a Banbury mixer, melt-extruded into a water bath and chopped into pellets. After drying, the pellets were extruded as a sheet 8.25 inch (21.0 cm) wide and 0.030 inch (0.076 cm) thick, and samples 6 inch (15.3 cm) square were cut from the sheet. Each sample was laminated between two metal foils 6×6×0.0014 inch in a heated press at 260° C. and 4,000 lb. pressure for 2 minutes, followed by 7,000 lb. pressure for 3 minutes. The metal foils were electrodeposited copper foils which had been passivated with nickel and zinc on the surface adjacent the sample. Such foils are available from Yates Industries under the trade name TEX-1. Disc-shaped devices 0.125 inch (0.318 cm) in diameter were punched from the laminates. A 24 AWG nickel-plated steel lead was attached to each metal foil on each device. The devices were then encapsulated by an epoxy resin which was cured at 110° C. for 3 hours. The physical and electrical stability of the foil/conductive polymer interface remained excellent under a wide variety of conditions. A device 10 of Example I is shown in FIG. 1. The device 10 comprises a laminar element 12 which is composed of a conductive polymer exhibiting PTC behavior and first and second electrodeposited metal foil electrodes (numerals 14 and 16), which electrodes 14 and 16 are in direct physical contact with a surface of the conductive polymer element 12. EXAMPLE 2 Following substantially the same procedure as in Example 1, devices were made from a conductive polymer containing the ingredients listed in the Table below. TABLE______________________________________ Example 1 Example 2 vol volIngredient wt (g) wt % % wt (g) wt % %______________________________________High density 6200 31.5 56.1 8092 49.3 63.9polyethylene(Marlex 6003)Carbon black 5310 27.0 25.7 -- -- --(Sterling SO)Carbon black -- -- -- 8071 49.0 34.1(Statex G)Titanium dioxide 7955 40.5 16.5 -- -- --(TiPure R101)Antioxidant 205 1.0 1.7 276 1.7 2.0______________________________________ NOTES: Marlex 6003 is available from Phillips Petroleum and is a high density polyethylene with a melt index of 0.3 and a melting point of about 135° C. Sterling SO is a carbon black available from Cabot. It has a particle siz of 41 millimicrons and a surface area of 42 m.sup.2 /g. Statex G is available from Columbian Chemicals and is a carbon black with a particle size of about 60 millimicrons and a surface area of 36 m.sup.2 /g. TiPure R101 is a titanium dioxide available from Du Pont. The antioxidant used was an oligomer of 4,4thiobis (3methyl-6-tert butyl phenol) with an average degree of polymerization of 34, as described in U.S. Pat. No. 3,986,981. EXAMPLE 3 The following ingredients were mixed following the above procedure. ______________________________________ wt. (g) wt. % vol. %______________________________________Carbon black 3,915 19.2 19.0(Vulcan XC-72)Polyvinylidene fluoride 15,701 76.8 77.5(KF 1000)Calcium Carbonate 618 3.0 2.0(Omya Bsh)Radiation cross-linking agent 199 1.0 1.5______________________________________ The pellets were extruded into a sheet 11 inch (27.9 cm) wide and 0.020 inch (0.051 cm) thick and were irradiated 20 Mrad using a 1.5 MeV electron beam. Samples 6 inch (15.3 cm) square were cut from the sheet. Two samples of polymer sheet were laminated between two (6×6 in) sheets of (1 ounce) electrodeposited copper foil by exposing to 1500 lbs pressure at 200° C. for 4 minutes, 20,000 lbs pressure for 2 minutes, before cooling at 20,000 lbs pressure in a water-cooled press. Such foils are available from International Foils. The resulting sheet was 0.035 inch (0.089 cm). Flat 0.005 inch (0.013 cm) copper leads were soldered onto 1 inch (2.54 cm)×2 inch (5.08 cm) samples cut from the slab. The heaters were then encapsulated in epoxy. KF 1000 is a polyvinylidene fluoride available from Kureha. Vulcan XC-72 is a carbon black available from Cabot with a particle size of 30 millimicrons and a surface area of 254 m 2 /g. Omya Bsh is CaCO 3 available from Omya Inc. The radiation cross-linking agent used is triallylisocyanurate.
Electrical devices which comprise at least one metal electrode and a conductive polymer element in contact therewith, wherein the metal surface which contacts the conductive polymer has a roughened or otherwise treated surface to improve its adhesion to the conductive polymer. The metal electrode is preferably an electrodeposited foil. The conductive polymer preferably exhibits PTC behavior. The devices include heaters and circuit protection devices. The improved adhesion results in improved physical and electrical stability, and broadens the range of conductive polymer compositions which can be used in a number of important applications.
5
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH This invention was made with Government support through a two year grant by the U.S. Environmental Protection Agency to the Hazardous Waste Research Center of Louisiana State University covering Jan. 1, 1985 to Dec. 31, 1986. The government may have certain rights in this invention. CROSS REFERENCE This application is related to co-pending application Ser. No. 892,312 filed on Aug. 4, 1986 entitled Detoxification of Chlorinated Aromatic Compounds by Organism NRRL B-18086. BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to detoxifying chlorinated aromatic compounds with enzymes produced from microorganisms. 2. Description of the Prior Art Chlorinated aromatic compounds such as 2,4, Dichlorophenoxyacetic Acid (2,4-D) were synthesized in recent decades out of industrial and agricultural necessity. Unfortunately, these toxic compounds are hazardous when released to the environment. Such releases may be purposeful, as occurs with pest control, or they may be by accident from leakage or improper waste control. Microbes occurring in nature did not have the necessary enzymes to degrade these compounds. However, due to continuous exposure of natural microorganisms to these xenebiotic chemicals, a few groups of microorganisms have developed an enzymatic system which is resistant to toxic compounds and are capable of degrading them at a slow rate. The evolution of microorganisms with biodegradable capability has occurred due to adaptation and furthermore, mainly from the mutations of extrachromosomal DNA replicons classified as plasmids. Plasmids play an important role in the adaptation of a mixed population to an environmental stress and they are capable of transmittal to intergenetic and intragenetic bacterial species to spread the necessary genetic information. The occurance of genetic information for catabolic pathways on extrachromosomal plasmid DNA has been known for several years. Also known is the capacity of various strains of Pseudomonas for catabolizing salicylate, camphor, octance and napthalene all of which have genetic information on their plasmids. (Chakraborty et al, "Genetic Regulation of Octane Dissimilation plasmid in Pseudomonas", Proc. Natl. Acad. Sci., 70, 1137-1140, 1973; Dunn and Gunsalus, "Transmissible Plasmid Coding Early Enzymes of Naphthalene Oxidation in Pseudomonas putida", J. Bacteriol., 114: 974-979, 1973; Rheinwald et al, "A transmissible Plasmid Controlling Camphor Oxidation in Pseudomonas putida", Proc. Natl. Acad. Sci., 70, 885-889, 1973). The existence of a plasmid in Pseudomonas putida which codes the necessary enzymes for the degradation of three aromatic compounds was known by 1974. The metabolic pathway requires at least two hydroxyl groups prior to the cleavage of the aromatic rings. (Dagley, "Catabolism of Aromatic Compounds by Microorganisms", Adv. Micro. Physiol., 6: 1-46, 1971). However, there is an exception with Bacillus brevis which was isolated from the contaminated Mississippi River. This strain has a enzyme which can degrade aromatic hydrocarbons with only one hydroxyl group. (Crawford et al, "Catabolism of 5 Chlorosalicylate by a Bacillus Isolated from The Mississippi River", Applied and Environmental Microbiology, Vol. 38, No. 3, 379-384, Sept. 1979). Recent research in this country has reported Pseudomonas cepacia strains capable of biodegrading halophenals with similar research in Russia and India where two other strains of Pseudomonas capable of biodegrading chlorinated organics have been reported. (Karns et al, "Regulation of 2,4 5 Trichlorophenoxyacetic Acid And Chlorophenol Metabolism In Pseudomonas cepacia Ac 100", Applied and Environmental Microbiology, 46, 5, 1182-1186, Nov. 1983; Karns et al, "Metabolism of Halophenols By 2,4,5 Trichlorophenoxyacetic Acid Degrading Pseudomonas cepacia", Applied and Environmental Microbiology, 46, 5, 1176-1181, Nov. 1983; Golovleva et al, "Degradation of Polychloroaromatic Insecticides by Pseudomonas aeruginosa Containing Biodegradation Plasmids"Translated from Mikrobiologiya, 51: No. 6, 973-978, 1982. Arunakumari and Mahadevan, "Utilization of Aromatic Substances by Pseudomonas solancearum", Indian Journal of Experimental Biology", 22, 32-36 Jan. 1984) It is normally hypothesized that biodegradation of chlorinated organics may be by the dehalogenase enzymes which are typically found in soil microorganisms. The presence of the dehalogenase enzymes in soil microorganisms has been observed in 16 isolates. Within these isolates four types of dehalogenase activity were noted. (Hardman and Slater, "Dehalogenases In Soil Bacterial", Jour. of General Microbiology, 123, 117-128, 1981). Pseudomonas have two dehalogenase enzymes, one of which is comparable to enzymes in other soil isolates whereas the second enzyme is unique to Psuedomonas. Microorganisms in nature have been noted to withstand inorganic toxic pollutants such as heavy metals. The fate and transport of heavy metals in the natural environment have been studied. In particular Thiobacillus ferroxidans has been found to be resistant to high concentrations of heavy metals. (Dissanayake, "Metal-Organic Interactions In Environmental Pollution", Intern. J. Environmental Studies, 22, 25-42, 1983). This was supported by experimental data showing the capability of Thiobacillus species containing plasmids which may encode heavy metal resistance. (Davidson and Summers, "Wide Host Range Plasmid Function In The Genus Thiobacillus", Applied and Environmental Microbiology, 46, 3, 565-572, Sept. 1983.) Microorganisms present in nature undergo genetic modifications and can cope with many toxic compounds under ideal conditions. (Slater and Bull, "Environmental Microbiology Biodegradation", Phil. Trans. Soc. Lond., B297, 575-579, 1982). However, most of what is known in this area has been performed using pure culture - pure substrate systems and available information of the growth kinetics of these microbes is relatively meager. In both natural and man-made environments, microbes are present in a diversity of substrates and their behavior is distinctly different from that of a pure system. (Harder and Dijrhuizen, "Strategies of Mixed Substrate Utilization in Microorganisms", Phil. Trans. R. Soc. Lond., B297, 459-480, 1982; Williams, "Genetic Interactions Between Mixed Microbial Populations", Phil. Trans. R. Soc. Lond., B297: 631-639, 1982). Biodegradation of an organic compound which is not necessarily a growth substrate can be accomplished by the process of co-metabolism. Co-metabolism is defined as the transformation of a non-growth substrate in the obligate presence of a growth substrate or another transformable compound. (Dalton and Stirling, "Co-Metabolism", Phil. Trans. R. Soc. Lond., B297, 481-496, 1982). Biodegradation of chlorinated organics as co-metabolites have been observed for Pseudomonas and soil microbes. (Francis et al, "Co-metabolism of DDT Analogs By A Pseudomonas Sp.", Applied and Environmental Microbiology, 35, 2, 364-367, Feb. 1978; Hartman et al, "Metabolism of 3-Chloro-, 4-Chloro-, and 3, 5-Dichlorobenzoate By a Pseudomonas", Applied and Environmental Microbiology, 37, 3, 421-428, Mar. 1979; Marinucci and Bartha, "Biodegradation of 1,2,3 and 1,2,4 Trichlorobenzene in Soil and in Liquid Enrichment Culture", Applied and Envorinmental Microbiology, 38, 5, 811-187, Nov. 1979). Enzymatic conversion of 2,4,5,T to 2,4,5 trichlorophenol (TCP) by Pseudomonas where conversion of TCP was repressed by an alternate carbon source has also been observed. (Karns et al, "Metabolism of Halophenols By 2,4,5 Trichlorophenoxyacetic Acid Degrading Pseudomonas cepacia", Applied and Environmental Microbiology, 46, 5, 1176-1181, Nov. 1983). Plasmids in microbes attribute biodegrading properties, but have a form of finite stability. Adaptative and environmental changes result in oscillations in the proportion of plasmid containing microorganisms. (Borisoglebskaya and Boronin, "Population Changes in the Pseudomonas putida strain BSA202 carrying plasmid NPL-1 for Naphthalene Catabolism", Translated from Mikrobiologiya, 52: No. 2, 301-306, 1983; Gorlatova and Golovleva, Population Dynamics of P-xylene Assimilating Pseudomonas aeruginosa", Translated from Mikrobiologiya, 52: No. 3, 392-395, 1983; Helling et al, "The Maintenance of Plasmid Containing Organisms in Populations of Escherichia coli", Jour. of General Microbiology, 123, 129-141, 1981; Ollis, "Industrial Fermentations With (Unstable) Recombination Cultures", Phil. Trans. R. Soc. Lond., B297 617-629, 1982). As the plasmid containing fraction of microorganisms are capable of biodegradation, the oscillation of the active fraction results in an oscillation of the rate of biodegradation. Also, the growth criteria of plasmid active species differ from those of plasmid free species. A survey of the prior art shows that although microbes capable of degrading hazardous organic and inorganic waste have been isolated, little is known regarding the growth kinetics and stability of these microbes in a mixed culture, multiple substrate system. A system which is the most comparable to the real world. Additionally, the prior art lacks information concerning the applicability of using microbial dehalogenase enzyme systems to detoxify chlorinated organic compounds. SUMMARY OF THE INVENTION A strain of the micro-organism Pseudomonas pseudoalcaligenes, NRRL B-18087, has now been found which is capable of producing dehalogenase enzymes which can biodegrade chloroaromatic compounds. An unrestricted deposit of this previously undescribed organism was made with the Agricultural Research Service Culture Collection on July 25, 1986, under Accession No. NRRL B-18087. The deposit has been accepted under the Budapest Treaty. All restrictions on the availability of progeny of the strain to the public will be irrevocably removed upon the granting of a patent of which the strain is a subject. DETAILED DESCRIPTION Through the process of selective enrichment, two new Pseudomonas bacteria capable of biodegrading chloroaromatic compounds have been isolated from the mixed microbial culture obtained from the Baton Rouge Sewage Treatment Plant. One of these bacteria isolates is the subject of the co-pending application Ser. No. 892,312 entitled Detoxification of Chlorinated Aromatic Compounds by Organism NRRL B-18086. The second bacteria isolate is the subject of this application. Routine biochemical tests were performed to determine the taxonomic classification of these isolates. The results of these tests for NRRL B-18087 are shown on Table 1 below. Based on these properties, a profile comparison was made with those included in the rapid NFT data base of DMS Laboratories, Inc., Plainview, N.Y. NRRL B-18087 was identifiable at the genus level to be Pseudomonas. This was further verified by independent testing conducted by API Analytab Products, Plainview, N.Y. TABLE 1______________________________________Characteristics of Pseudomonas Isolates NRRL B-18087 Pseudomonas IsolateTest NRRL B-18087______________________________________1. Gram Stainve2. Shape Short Rods3. Flagella Petritrichious4. Motility +5. Pigment Pale Yellow6. G + C % 59.27. Growth 30° + 35° + 25° + 42° -8. Oxidase +9. Catalase +10. Fermentor -11. Glucose Oxidizer -12. Growth Blood Agar + small colony Nutrient Agar + MacConkey Agar - Peptone-Yeast Ex. + Peptone-Agar + (Ps. Agar) Cetrimide -13. TSI No change14. H.sub.2 S -15. Nitrate Reduction +16. Nitrite Reduction -17. Tryptophanase -18. Arginine Dehydrolase -19. Lysine Decarboxylase -20. Urease -21. Ornithine Decarboxylase -22. Esculin Hydrolysis -23. Tryptophan Deaminase -24. Gelatinase -25. Beta-d-galacto-sidase -26. O--nitrophenyl- -d- galactoside -27. Arabinose -28. Mannose -29. Rhamnose -30. Saccharose (sucrose) -31. Melibiose -32. Maltose -33. Inositol -34. Sorbitol -35. N--acetyl-glucosamine -36. Gluconate +37. Caprate +38. Adipate +39. Malate +40. Citrate +41. Phenyl Acetate +42. Amygdalin -43. Indole Production -44. Voges-Proskauer Test -______________________________________ Isolates NRRL B-18087 is gram negative, nonfermentative, motile rod. It is pale yellow in color with an approximate size of 2.7×1.1 μwith peritrichious flagella. The mean guanine plus cytosine (GC) content of the chromosomal DNA of the isolate was obtained from the cesium chloride buoyant density determined by analytical ultracentrifuge. The GC content of the isolate using poly dAT standards was calculated to be 59.2. The newly isolated strain of Pseudomonas is capable of utilizing chlorinated aromatic compounds as the sole carbon source. NRRL B-18087 appears to be a new species, based on biochemical and morphological properties. The isolate contains dehalogenase activities and the enzyme can be detected by release of Cl - from the 2,4-dichlorophenoxyacetic acid (2,4D), 2,4-dichlorophenol, 2,4,5-trichlorophenoxyacetic acid (2,4,5T), 2,4,5-trichlorophenol, pentachlorophenol and 3-chlorobenzoic acid, in both the culture medium and after incubation of cell free extracts with the chlorinated compounds. Electrophoresis of cell-free extracts in native polyacrylamide gel and staining for Cl - after incubation with 2,4-D and 2,4,5-T show multiple bands of enzyme activities which are unique for the isolate and also distinct from those of Alcaligenes eutrophus, which is also known to contain enzymes for the degradation of the aromatic chloro-compounds. The enzymes expressed by NRRL B-18087 can be used to detoxify a large group of chlorinated organics. Pseudomonas NRRL B-18087 was grown and maintained in a Basal Salt Medium with 2, 4-D, although other media conditions can be used. The composition of the medium used for one liter of water is given below: ______________________________________2, 4 D - 1.7 gmK.sub.2 HPO.sub.4 - 5.8 gmKH.sub.2 PO.sub.4 - 4.5 gm(NH.sub.4).sub.2 SO.sub.4 - 2.0 gmMgCl.sub.2 → 0.16 gmCaCl.sub.2 → 20.0 mgNaMoO.sub.4 → 2.0 mgMnCl.sub.2 → 1.0 mgIn One (1) Liter______________________________________
Pseudomonas pseudoalcaligenes strain NRRL B-18087 was isolated as a pure culture from the Baton Rouge sewage treatment plant. The strain can utilize chlorinated aromatic compounds as the sole carbon source and will degrade both 2,4-dichlorophenoxyacetic acid (2,4-D) and 2,4,5-trichlorophenoxyacetic acid (2,4,5-T), as well as other xenobiotic compounds.
8
SUMMARY OF THE INVENTION It is an object of this invention to describe an apparatus for sorting plural bit records, the sorting time being in overlap relation with record loading and unloading. The apparatus of the invention can be visualized as a U-shaped pipeline processing path with normal data flow down the left arm along the U and up the right arm. Crosspaths between the two arms are provided to facilitate data exchange. The input records with their identifiers are loaded sequentially down the left arm, and records after processing emerge from the top of the right arm. The identifiers in the valid records, which are moving up along the right arm, are selectively compared with those in the valid records moving down the left arm. Either the original records or their permulation will, in one time cycle, arrive at the next downstream positions along the U-tube. Normal flow without exchange occurs if the comparisons involve invalid records, and output is suppressed if both records are invalid. The operations using this structure advantageously overlaps the sorting time with synchronized loading and unloading. The pipeline processing path is formed from a plurality of logical building blocks, called steering units. Each steering unit has the topology of a slanted "figure 8" with an upper left cell and a lower right cell. The steering units are stacked together. The stacked left cells form a left arm to support downward data flow, while the stacked right cells form the right arm to support upward data flow. The linkage between the two arms, as well as the final exit from U-shaped apparatus, each make use of buffer cells which could be considered to be partly disabled steering units. Reference is made to U.S. Letters Pat. No. 3,997,880 to T. C. Chen, et. al., U.S. Ser. No. 556,377, filed Mar. 7, 1975, entitled "An Apparatus and Machine Implementable Method for the Dynamic Rearrangement of Plural Bit Equal Length Records", and to U.S. Letters Pat. No. 4,078,260, co-pending application to T. C. Chen, et. al., U.S. Ser. No. 685,859 filed on May 12, 1976 entitled "An Apparatus for Transposition Sorting of Equal Lengths Records in Overlap Relation with Record Loading and Extraction". The Ser. No. 685,859 application is directed to minimizing the total time of serially loading, sorting, and unloading records into and from uniform ladder structures of the type described in U.S. Pat. No. 3,997,880. Each uniform ladder structure in said references is formed from equal length loops fillable with equal length records. The loops are coupled into a linear array by dual mode switches implementable in magnetic bubble technology. The apparatus described in the Ser. No. 685,859 application minimizes processing time by over-lapping the sorting of records with the serial loading and unloading process via the critical use of multiple uniform ladders of unequal length. This permits sorting in a number of filled long ladders while the remaining shorter ladders are being loaded or are awaiting loading. The process of overlapping the sorting of the contents of the longer ladders with the loading of the shorter ladders results in all of the ladders having their contents sorted by the time the shortest ladder is filled. The partially sorted results are then merged with each other in a separate pass, as the ladders are unloaded. Advantageously, the pipeline sorter of the instant invention, also denominated, "rebound sorter", is not limited to magnetic bubble or shift-register technology, and need not be serial. It requires only a single processing path combined with logic to exchange and advance records at preselected points along the path. This is accomplished by topologically folding over a linear path into a U-shape and providing sensing/comparison and exchange mechanisms between the contents at preselected correlated points in the two arms of the U. For the sorting of N records, the apparatus requires 2N cells. Of these 2N-2 cells are arranged into (N-1) steering units with the addition of one buffer cell coupling the upward/downward arms and one other buffer cell serving as an output buffer. On the basis that two time cycles are used to load each record into the apparatus, it has been found that starting at time t o , the first comparison starts at time t o +(N+1) cycles the first sorted record emerges at t o +(2N+1) cycles, the last comparison occurs at t o +(3N-3) cycles, and the last sorted record exits from the apparatus at time t o +(4N-1) cycles. The advantages of the rebound sorter over the Ser. No. 685,859 invention are: 1. It is implementable in a variety of data processing technologies. 2. It can be either word-parallel or serial by any data width. 3. It uses only one pipeline data path. There is no need for merging the results as in Ser. No. 685,859. 4. In Ser. No. 685,859 each ladder is almost fully loaded before any comparison can begin. Here comparison begins as soon as more than half of the records have entered the U-tube. DESCRIPTION OF THE DRAWING FIG. 1 shows the building blocks and their external linkage. FIG. 2 sets forth a rebound sorter formed from unit cells. FIG. 3 illustrates the logical implementation of the rebound sorter of FIG. 2. FIG. 4 depicts the sorting action of the invention. FIG. 5 sets forth a typical format for plural bit records of the type suitable for use in the invention. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to FIG. 5, there is shown the format for each record, where the identifier may begin at any bit position, and may consist of up to the entire record. Each of the records inside the apparatus is accompanied by a validity indicator. The monitoring for validity and comparison of identifiers are needed to decide on the swapping or sorting of records. We shall now describe a preferred embodiment. N records in general can be sorted using (N-1) steering units plus two buffer cells. For convenience, we shall limit N to 4. The generalization to other values of N is straightforward. We shall also limit the records to sizes no larger than a cell register can contain; these records nevertheless need not be fixed in size, as each can be padded with extra zero bits to fit the register. Referring now to FIG. 1, there is shown in drawings A, B, and C the constituents of the rebound sorter. In FIG. 1A, the primary logical element, termed a "steering unit" has the appearance of slanted "figure 8" with an upper left cell L and a lower right cell R. Each steering unit cell has a register to hold one record, and possesses vertical and horizontal input/output ports. During operation, only two of the four output lines for a steering unit may be activated, either the two horizontal lines (h L out , h R out ) or the two vertical lines (v L out , v R out ). The criterion for selective activation of the lines is based on a comparison rule of action between the identifier associated with the valid record in the left cell, versus the identifier for the valid record in the right cell. Assuming it is intended to sort records in ascending order, the record having the smaller identifier would emerge at h L out or V R out , while the record having the higher identifier would emerge at v L out or h R out . The presence of invalid records call for special handling. This is formulated in the following rule for ascending order sorting. If C(L)≧C(R), or if invalid record is present, activate vertical output lines (normal flow); Else: activate horizontal output lines (abnormal flow). Descending order sorting obtains by replacing the ≧ sign by the ≦ sign. The bottom cell (FIG. 1B) and the top cell (FIG. 1C) are truncated and simplified versions of a L and R cell respectively of a steering unit. They serve no comparison function, providing only mandatory output with delay consequent to input from one of the two input lines. The rebound sorter is assembled with stacked steering units plus the two buffer cells, as shown in FIG. 2. The left cells are stacked through the alignment of their vertical ports to form a left arm to support downward data flow, while the right cells are also stacked with their vertical ports aligned to form a right arm to support upward data flow. The upward and downward data motion will be considered normal. The horizontal ports are correspondingly aligned to enable crosspath flow between the two arms. The stacked steering units are complemented at the lower left by a bottom unit, and at the upper right by a top unit, with vertical and horizontal ports properly aligned. In FIG. 2, the assemblage forms a rebound sorter for four records. The left arm of the U-shaped path is formed by input 1, steering units cells S1L, S2L, S3L, bottom cell B (which can be considered to be S4L) and connecting paths 5, 9, and 13. The right arm is formed by steering units cells S3R, S2R, S1R, top cell T, (which can be considered to be S0R) and connecting paths 21, 27, and 33. Bottom unit B operates as a pivot coupling the left and right arms. By identifying h R out of an upper steering unit with h L in of the steering unit immediately below, also by identifying h L out of a steering unit with h R in of the steering unit immediately above, crosspaths are provided to link the two arms at regular intervals. These crosspaths are: paths 17, 19, which link bottom unit B with steering unit cell S3R; paths 23 and 25 link steering units cells S3L with S2R; paths 29 and 31 which link steering unit cells S2L with S1B, and finally S1L is linked to the top cell T via path 37. The horizontal input line to S1L is disabled, likewise the vertical input line to S3R. These disabled lines can be considered to have fixed zero input, as shown in FIG. 2. Significantly, in this logical arrangement every unit is pulsed simultaneously and periodically with uniform lapsed time cycles. Each of the steering units may receive a pair of valid records, compares them and emits them through either horizontal or vertical paths in one time cycle. The steering units with no valid record in either of the cells have no valid output and can be given normal vertical output. Those units with exactly one invalid record have normal vertical output. The top unit T receives its input from the topmost steering unit cell S1R into its one record buffer, then transmits the record upward out of the system in one cycle. Likewise, the bottom unit B receives its input from the lowest steering unit S3L and sends the record horizontally to steering unit S3R over path 19 in one cycle. All input records are provided with a validity indicator, which needs only to take one bit. All data transmission internal to the rebound sorter are performed with the accompaniment of the validity indicator. Upon exit, this indicator may be stripped off the valid records. The entire system is capable of accepting one record in two cycles, and eject one record in two cycles. Any steering unit will be idle at alternate cycles; but during a working cycle, will receive a pair of inputs, compare and emit them all in one cycle. FIG. 3 is a logic level implementation of the 4-record rebound sorter of FIG. 2. Each of the steering units (S1L,R), (S2L,R), and (S3L,R) includes two storage registers, one in each cell. Each register is capable of holding one record and providing validity indication. Each of the steering units further include circuitry for checking validity, comparing record identifiers, and a gating arrangement for sending the records stored in the L,R cells along either the vertical output paths or the horizontal output paths. The logical circuits can be implemented using standard flip-flops, AND, OR, EXCLUSIVE OR gates. These circuits are of well known and standard design and are not in themselves the object of this invention. Reference can be made by one having skill in the art to a number of standard works as for example: R. K. Richards, "Digital Design" Wiley-Interscience, New York 1971, p. 461-462. Referring again to FIG. 3, records to be sorted enter sequentially via path 1 to steering unit cell S1L where they are loaded into register 43 and are provided with validity indicators. At the same time that register 43 is loaded with a new record, register 59 in SlR is loaded with a record and its validity indicator, transferred from register 79 through AND gate 75 and path 27 or from register 63 through AND gate 67 and path 31. Both the identifiers and indicators from registers 43 and 59 are sent to comparator 51 over paths 45 and 61 respectively. A signal indicative of the results of, for exmple, a relative magnitude comparison between the identifiers is transmitted via paths 53 to the AND gate cluster 47, 49, 55, and 57 for selective output. A binary 0 transmitted through path 53, for example, will lead to 0 output from AND gates 47 and 57, blocking the horizontal crosspaths, while enabling AND gates 49 and 55 to transmit contents of 43 and 59 respectively, at the proper time signal, along the normal vertical flow direction. Conversely, a comparison result of 1 on path 53 will disallow AND gates 49, 55 to transmit along the normal vertical direction, while enabling AND gates 47 and 57 to transmit contents of 43 and 59 respectively along the crosspaths in "abnormal" delivery. The detailed transfer paths are as follows: For 0 result in path 53 (normal delivery): Upon proper time signal, the record stored in register 43 in steering unit cell S1L is transmitted vertically via path 45, AND gate 49, and path 5 to register 63 in unit cell S2L. The record stored in register 59 steering unit cell S1R is transmitted vertically via path 61, AND gate 55 and path 33 to register 40 in top unit T. The crosspaths 29, 39 deliver 0's without affecting the register contents of registers 63 and 40. For 1 result in path 53 (abnormal delivery): Upon proper time signal, the record stored in register 43 in S1L is transmitted horizontally via path 45, and gate 47, path 57 to register 40 in top unit T. The record stored in register 59 in S1R is transmitted horizontally via path 61, AND gate 57, path 29 to register 63 steering unit cell S2L. The vertical paths 5, 33 deliver 0's with no effect on registers 63 and 40. The above is generalizable to all steering units for an N-record sorter, B is called SNL, and T is called SOR below for convenience. If steering unit Sj issues a comparison result of 0 (normal delivery) the horizontal output paths will be blocked, and vertical paths will be enabled upon proper time signal to deliver contents of SjL to S(j+1)L contents of SjR to S(j-1)R. If steering unit Sj issues a comparison result of 1 (abnormal delivery) the vertical output paths will be blocked, but horizontal crosspaths will be enabled upon proper time signal to deliver contents of SjL to (S(J-1)R, contents, of SjR to S(J+1)L. The operation of the top and bottom unit differs only in a minor regard from that of the steering units. The output of B is always along a crosspath (in FIG. 3, path 105, AND gate 107, path 19 to register 99 in steering unit cell S3R). The output of T is always along a normal path (AND gate 42, path 41). There is no active crosspath to deliver T contents norizontally to S1L; for symmetry the horizontal input to S1L is marked with 0 input. Likewise, there is no valid active vertical input to S3R; the line is marked with 0 input. A discussion of timing is in order here. At time t o , deliveries of the input records begin, in such a way that the first record reaches S1L in t o + 1 cycles, the K-th record in t o + 2K+1 cycles. All odd-labelled units S1, S3, . . .,S(2J-1), . . . (S(N-1) or SN) must be serviced during the "odd" cycle starting at t o +2k+1, namely within [t o+ 2k+1, t o+ 2k+2). Likewise, all even-labelled units S0, S2, . . ., S (2j), . . . (S(N-1) or SN) must be serviced during the "even" cycle starting at t o +2k+2, namely within [t o +2k +2, t o +2k+3). And the service of a steering unit consists of: first, select identifiers and validity indicators, compare and issue compare result (0 or 1) next, based on the compare result, activate AND gates controlling either the horizontal or the vertical passage to allow movement of contents into a neighboring cell. During odd cycles, the even-labelled units could be serviced, but must not produce an interferring result, this is true for the odd-levelled units during even cycles. It is seen that during these times, the steering units with mismatched time parity do not have valid contents. The preferred embodiment is not to activate steering units with mismatched time parity, except to receive results from active steering units. In the interest of conciseness, the details in the clocking circuitry has been omitted in FIG. 3, excepting a gate connecting to the outside, labelled "time signal". The resetting of the apparatus registers into an invalid state is also briefly represented by an external connection labelled "reset". FIG. 4 depicts the dynamics in the use of the sorter FIG. 3 to sort four records C,B,D,A into A,B,C,D with (Identifier of A)<(Identifier of B)<(Identifier of C)<(Identifier of D). At time t o , the records are outside the sorter, the contents in the registers are all reset to "invalid". At time t o +1 cycle First record (C) has entered register 43 of S1L, and steering units S1,S3 are activated. S3 contains only invalid or extraneous contents, and lead to no significant outcome. In S1, the case is a valid record (in S1L) versus an invalid record (in S1R), leading to a normal delivery signal of 0 in 53, resulting in the transfer of C from 43 to 63 and incidentally an invalid record from 59 to 40. We shall not describe invalid record movement unless they have impact on the valid results. At time t o +2 cycles, even numbered steering units are activated; these include S2, also T (alias S0R) and B (alias S4L). The comparison shows that only S2L has valid contents, which is transmitted normally from 63 to 83. During this transmission time interval, the second record (B) enters registers 43 of S1L. As time T o +3 cycles, S1,S3, are activated, with S1L,S3L, delivering valid contents from registers 43, 83 to 63, 103 respectively. At time t o +4 cycles S0R,S2,S4L are activated. The active full steering unit S2 will deliver B from register 63 to 83. The bottom unit S4L makes a mandatory crosspath transfer of C from register 103 to 99 in S3R. Meanwhile a third record (D) enters register 43 in S1L. At t o +5 cycles, with the activation of S1,S3, a true comparison between two valid records is made in S3, leading to a compare result 1, and subsequent crosspath transfer of B from 99 to 103 in S4L, C from 83 to 79 in S2R, S1 has only one valid record, and executes a normal vertical flow from 43 to 63 in S2L. At t 0 +6 cycles, activation of SOR, S2, S4L leads to true compare in S2 resulting in vertical flow, also mandatory crosspath from S4L. At t o +7 cycles, activation of S1,S3 both involve true comparisons. S1 leads to crosspath flow because A,B have been in the incorrect juxtaposition. S2 leads to normal vertical flow since C,D are correctly positioned. The last input record (A) enters S1L. The entered set of inputs are in the sorter. At t o +8 cycles S0R,S2,S4L are activated. S2 leads to crosspath flow. S4L executes mandatory crosspath flow, and SOR executes mandatory vertical flow, yielding A from register 40 thrugh AND gate 42, path 41 to the outside, as global output. At t o +9 cycles S1, S3 are activated, S3 leading to crosspath flow. The contents of S1L is invalid, leading to normal vertical flow of S1R contents to S0R. At t o +10 cycles, S0R yields the second valid result(B). At t o +11 cycles S1L,S3L both have invalid contents leading to normal vertical flow. This normal flow persists through the rest of the sorting task. At t o +15 cycles the last record (D) has emerged and the sorting task is complete. The rebound sorter for N records can be assembled from (N-1) steering units, S1,S2, . . . S(N-1), plus a bottom cell B (SNL) just below S(N-1)L, and a top cell T (S0R) just above S1R. All vertical input-output ports are aligned, to provide normal vertical flow down the left arm and up the right arm. All horizontal input-output ports are also aligned to provide crosspath flow. The vertical input to S(N-1)R is always 0, as is the horizontal input to S1L. FIGS. 2 and 3 furnish the description of the special case N=4. To sort N records starting at time t o , the first record enters S1L at the end of the zeroth cycle [t o ,t o +1). The jth record enters S1L at the end of the 2j-th cycle [t o +2j, t o +2j+1). All odd steering units (S1,S3, . . .) are active during odd cycles [t o +2k+1, t o +2k+2), and all even steering units (S0,S2,S4, . . .) are active during even cycles [t o +2k+2, t o +2k+3). The top cell T is treated here as S0R, the right cell of an even steering unit. The bottom cell is treated here as SNL, the left cell of SN; the latter is odd or even dependent on whether N is odd or even. The comparison rules for active steering unit SK are, for ascending order: If (contents of L)≦(contents of R), or if either or both records are invalid, then issue compare result=0 to activate vertical output gates and deliver contents of SKL to S(k+1)L, and contents of SKR to S(k-1)R. Else compare result=1, activating crosspath gates to deliver contents of SKL to S(k-1)R, contents of SKR to S(k+1)L. (For descending order ≧ is replaced by ≦ above). Then upon t=t o +(N+1) cycles the first true comparison begins. t=t o +(2N-1) cycles the first output emerges out of S0R. t=t o =(3N=3) cycles the last time comparison begins. t=t o +(4N-1) cycles the last output emerges. Sorting is complete. The sorting will be overlapped completely with loading (t o , t o +2N cycles), and unloading (t o +2N+1, t o +4N-1). As inferred before, the rebound sorter can be implemented in a variety of ways. As the input/output rate is one record per two cycles, and as comparisons occur twice as frequently, the embodiment is most efficient for those records which are inherently slow in motion relative to decisions. Certainly, source records from slow storage devices, also serially accessed records both have this property. For serial records, the access path widths can be reduced down to one bit wide for bit-serial records or one byte (6 to 8 bits) wide for byte-serial records for cost and space economy. Consequently, it will take more than one time interval to move a complete record. On the other hand, comparisons are made on record identifiers which usually occupy only a small portion of the record length and can be done rapidly by modern electronic means. Indeed, the identifiers can even be collected or copied, then compared by a separate, external fast device, as long as the records move in accordance with the corresponding comparison outcome. It is apparent that embodiments can be fashioned in any one of a number of technologies; as for example, magnetic bubbles, charge couple devices, and semiconductor integrated circuit electronics or their proper admixture. Of importance is the fact that the rebound sorter requires only a single processing path and the logic to exchange and advance records at preselected points along the path. This is accomplished by folding over the path into a (U) shape and providing a sensing/comparison and exchange mechanism between the contents at preselected points. As soon as more than N/2 records have entered the pipeline, then sorting action can take place. In co-pending application, 859 no comparison can occur until N-2 records have been loaded. While in accordance with the provisions and statutes, there has been illustrated and described the best mode of the invention presently known, changes may be made in the system described without departing from the spirit of the invention as set forth in the appended claims. Some of these desirable changes are delineated below: First, roughly half of the steering units are idle at any time, because during odd time cycles only odd-labelled steering units are needed, and during even time cycles only even-labelled steering units are needed. One economizing improvement is to share one comparator between two neighboring steering units, so that it serves odd-labelled units during odd cycles, and even-labelled units during even cycles. If the number N of records is odd, this sharing is perfect because the number of steering units is an even number. For an even N, one steering unit will be left over and need to contain its own comparison unit. Higher order of sharing of comparison units is possible as long as the overall comparison rate is maintained. It is also possible to do all comparisons outside the sorter, if the identifiers are copied or extracted, and are compared elsewhere. The compare result signals are fed into the simplified units. Secondly, a small modification of the sorter is able to accommodate records up to twice the length of a steering unit register, provided that the identifier in each record is in the front portion of the record, and can be contained completely in one register. The "tail" segment of the record then occupies an adjacent cell, and always follows the movement of the front segment, lagging behind by exactly one cycle. Also, apparatus of the invention may be modified in order to facilitate the comparison of records longer than one register in length. This adjustment in the gating and buffering is one such that the comparison result signal in every active steering unit will control for two successive cycles the output of the registers in both cells during the later phase of the active cycle and the next cycle at which time the comparison mechanisms are disabled. This adjustment will allow the second part of a long record to follow the flow of the first part which contains the identifier and the proper validity indicators, without interfering with any delivery of the active steering units. This feature will enable long records to enter the apparatus in two segments, the second segment following the leading segment exactly by one time cycle throughout the sorting run. The input/output rate for this double precision flow remains the same as before, namely at one record per two time cycles. Thirdly, a rebound sorter may have 2N cells, capable of sorting N records. It should also be able to sort a smaller number (say M) of records. This is done easily by enforcing a compulsory crosspath flow from the left cell of S(M+1), this left cell in effect is degenerated into a bottom cell. Many techniques can be invoked to do this. The preferred embodiment is to bias the critical comparator to generate only 1 signals during this smaller sorting task. Another way is to use fictitious data to achieve this comparison result signal. Fourthly the top buffer cell (T or S0R in FIG. 3) is just a convenient place to provide a global exit. It can be replaced by DOT-ORing the two source paths h R in and v R in into the output path. The results will emerge one cycle earlier by this simplification.
This invention describes a pipeline sorter, in which record-pairs are compared and conditionally swapped while being advanced along the pipeline synchronously. The pipeline sorter has the topology of a U-shaped tube, with regularly spaced crosspaths linking the two arms. Records are loaded one at a time, into the input arm synchronously, and emerge out of the output arm, also one at a time and synchronously. Within the sorter, at periodic time intervals a number of record-pairs at correlated positions of the U-tube are compared. Dependent on the comparison outcome, either the original records themselves, moving along vertical paths, or their permutation, moving along crosspaths, will arrive at the next down-stream positions. In this manner, as soon as the last record has been loaded, the correctly sorted output will begin to emerge, with the overall sorting time completely overlapped by the loading and unloading of records.
6
BACKGROUND OF THE INVENTION [0001] 1. Technical Field [0002] This invention relates generally to packaging and containers. More particularly, the invention relates to lockable containers. Specifically, the invention relates to a lockable container that includes a sleeve that holds a product and slides into a jacket to prevent access to the product. An alarm mechanism is provided that is armed simultaneously when a locking mechanism is locked and is disarmed simultaneously as the locking mechanism is unlocked. [0003] 2. Background Information [0004] Many stores sell articles of merchandise that are expensive. In such instances, it frequently is necessary to display these valuable articles in such a way that would-be thieves are deterred from stealing the article or are hindered in doing so. If the article of merchandise is fairly large, it is relatively easy for a store to detect if a thief is removing the same from a display or attempting to get the article past a security system such as security gates at the exit to the store. Additionally, larger articles provide ample opportunity for the store to attach security tags, such as RFID tags, to the article itself or to its packaging. Numerous other security measures have been invented to protect these larger articles including specialized securement systems which prevent tampering with packaging, alarmed tethers to secure articles to displays etc. [0005] Smaller articles of merchandise are far more problematic for retailers simply because of their size. Smaller articles are relatively easy for a would-be thief to slip into their clothing or into a pocket or purse. It is extremely difficult to attach security measures such as RFID tags to these smaller items and the articles can be unsuitable for tethering to displays. [0006] There is therefore a need in the art for a security device that can be used to deter would-be thieves from stealing smaller articles of merchandise. BRIEF SUMMARY OF THE INVENTION [0007] The device of the present invention is a security container for holding a product. The container includes a jacket having a cavity, a sleeve receivable in the cavity, and a chamber in the sleeve for holding the product. The sleeve moves within the cavity between a position where a user can access the chamber and a position where they cannot access the chamber. A locking mechanism secures the sleeve against movement when in the locked condition and permits movement thereof when unlocked. An alarm mechanism is provided that is simultaneously activated when the locking mechanism is locked and deactivated when the locking mechanism is unlocked. The locking mechanism includes a magnetic locking member movable by a dedicated magnetic key to unlock the mechanism. The security container is adjustable in length to accommodate products of different sizes. The container preferably is of a diminutive size in that it is capable of fitting into a man's dress shirt pocket. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS [0008] The preferred embodiments of the invention, illustrative of the best mode in which Applicant contemplates applying the principles, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims. [0009] FIG. 1 is a perspective view of a first embodiment of a security container in accordance with the present invention shown in a locked condition and including a hanger member for suspending the container from a display rod; [0010] FIG. 2A is an exploded perspective front view of the inner sleeve of the security container of FIG. 1 ; [0011] FIG. 2B is an exploded perspective front view of the outer jacket of the security container of FIG. 1 ; [0012] FIG. 3 is an exploded perspective rear view of the inner sleeve of the security container of FIG. 1 shown without the hanger member; [0013] FIG. 4 is a front perspective view of a catch used for latching the outer jacket and the inner sleeve together to prevent the sleeve from fully disengaged from the jacket; [0014] FIG. 5 is a rear perspective view of the catch of FIG. 4 ; [0015] FIG. 6 is a front cross-sectional view of the engaged sleeve and jacket taken along line 6 - 6 of FIG. 1 , showing the hanger member engaged with the top wall of the sleeve; [0016] FIG. 7 is a top cross-sectional view of the engaged sleeve and jacket taken along line 7 - 7 of FIG. 1 , showing the locator guide walls engaging the sleeve and keeping the same in the correct alignment with respect to the jacket's inner surface; [0017] FIG. 8 is a left-side cross-sectional view of the engaged sleeve and jacket taken along line 8 - 8 of FIG. 1 , showing the catch and the compartment housing the alarm mechanism; [0018] FIG. 9 is a left-side cross-sectional view of the engaged sleeve and jacket taken along line 9 - 9 of FIG. 1 and showing the locking mechanism in a locked condition; [0019] FIG. 10 is a left-side cross-sectional view of the engaged sleeve and jacket taken along line 9 - 9 of FIG. 1 and showing a magnetic key engaged with the security container and the locking mechanism in an unlocked condition; [0020] FIG. 11 is a perspective front view of the security container in a first or open position and showing a product being inserted into the chamber of the sleeve; [0021] FIG. 12 is a left-side cross-sectional view of the security container taken through line 12 - 12 of FIG. 11 , showing the catch engaged in the slot and preventing withdrawal of the sleeve from the cavity of the jacket; [0022] FIG. 13 is a perspective front view of a second embodiment of a security container in accordance with the present invention, show in a locked condition; [0023] FIG. 14 is a left-side cross-sectional view of the security container taken along line 14 - 14 of FIG. 13 and showing the second embodiment of a locking mechanism which enables the overall length of the security container to be changed; [0024] FIG. 15 is an enlargement of the highlighted region of FIG. 14 showing the hooked end of the arm of the spring clip locking member engaged with a rack disposed on the side wall of the sleeve; and [0025] FIG. 16 is a perspective front view of the security container shown adjusted to a longer overall length to accommodate a longer product. Similar numbers refer to similar parts throughout the drawings. DETAILED DESCRIPTION OF THE INVENTION [0026] Referring to FIGS. 1-12 there is shown a first embodiment of a security container in accordance with the present invention, generally indicated at 10 . Security container 10 comprises an outer jacket 12 and an inner sleeve 14 that are engageable with each other to surround and protect a product and to provide security thereto to prevent theft of that product. Particularly, outer jacket 12 and inner sleeve 14 are slidably engageable with each other along a longitudinal axis “Y” ( FIG. 6 ). Both jacket 12 and sleeve 14 preferably are molded from a rigid plastic material although other suitable materials such as metals may also be utilized to manufacture the same. [0027] As will be described in detail hereinafter, sleeve 14 is configured to carry small articles of merchandise, such as product “P” ( FIG. 11 ) and it should be understood that security container 10 preferably is of a size that is small enough to fit into a man's dress shirt pocket. Particularly, product “P′ is a small product that is relatively expensive and is difficult to display without putting it at risk for theft. An example of the type of product “P” that could be secured inside security container 10 is a small perfume bottle or a small box containing a perfume bottle. Sleeve 4 is slidably movable into a cavity 22 ( FIG. 2B ) defined by jacket 12 . When product “P” is engaged in a chamber 36 ( FIG. 2A ) in sleeve 14 , sleeve 14 is moved further inwardly into cavity 22 ( FIG. 2B ) defined by jacket 12 to block access to the chamber 36 . When sleeve reaches a certain position in cavity 22 , a locking mechanism 16 within container 10 is moved from an unlocked condition to a locked condition. This substantially prevents further longitudinal movement of sleeve 14 relative to jacket 12 and simultaneously causes an alarm mechanism 18 within security container 10 to move from an unarmed condition to an armed condition. Alarm mechanism 18 may be of any type but preferably is a three-way alarm that is triggered if a would-be-thief attempts to break into security container 10 or if they try to pass through a secured exit to a store with security container 10 . Once security container 10 is locked by locking mechanism 16 and alarm mechanism 18 is activated, security container 10 is then able to be displayed for sale of the product “P” therein. Security container 10 may be placed on a shelf of a display or may be hung from a hang tag, as will be described further herein. When the consumer takes the security container 10 through the checkout at a store, the store employee will disarm alarm mechanism 18 utilizing a specially configured key “K” ( FIG. 10 ). The disarming of alarm mechanism 18 will simultaneously unlock locking mechanism 16 . Inner sleeve 14 is then able to slide outwardly from cavity 22 of jacket 12 and product “P” may then be removed from chamber 36 ( FIG. 2A ) of sleeve 14 . Security container 10 is then able to be utilized to secure another product for display and sale. [0028] Still referring to FIGS. 1-12 and especially FIG. 2B , all of the components which are incorporated into security container 10 and the manner in which they interact will now be described in greater detail. [0029] Outer jacket 12 includes a front wall 20 a , a back wall 20 b , a left side wall 20 c , a right side wall 20 d and a bottom or end wall 20 e ( FIG. 3 ). It should be understood that the terms “front”, “back”, “left”, “right”, “top”, “upper”, and “bottom” are used only to refer to the orientation of the components as shown in the drawings. The actual security container 10 may be used in any orientation. Walls 20 a - 20 e bound and define a cavity 22 . Front wall 20 a , back wall 20 b , and left and right side walls 20 c , 20 d terminate in an upper edge 24 that bounds and defines an opening (unnumbered) to cavity 22 . A shoulder 24 a is slightly recessed a distance inwardly from the edge 24 . Security container 10 has a longitudinal axis “Y” which extends from upper edge 24 of jacket 12 through to bottom wall 20 e thereof. Each wall 20 a - 20 d extends substantially parallel to longitudinal axis “Y” and bottom wall 20 e and edge 24 are disposed at right angles thereto. FIG. 2B also shows that edge 24 of jacket 12 defines two opposed notches 25 , one in the front wall 20 a and one in the rear wall 20 b . The purpose of notches 25 will be described further herein. [0030] It will be understood that at least some or all of back wall 20 b preferably is made from a transparent material so that a portion of the interior chamber 36 ( FIG. 2A ) of sleeve 14 of security container 10 may be seen through an aligned window 38 ( FIG. 3 ) of sleeve 14 . Back wall 20 b may, alternatively, be made from a non-transparent or opaque material along with the rest of the security container 10 so that the interior of the security container 10 is not visible to the consumer. Still further, all of the walls other than those that cover the locking mechanism 16 and alarm mechanism 18 may be made from transparent materials. It is desirable that at least the regions of the security container which include the locking mechanism 16 and alarm mechanism 18 are not transparent to that the exact nature of those components cannot be examined by would-be thieves. [0031] Front wall 20 a of jacket 12 meets left side wall 20 c thereof along a longitudinally extending corner 26 . Front wall 20 a defines a slot 28 ( FIG. 2B ) and an aperture 30 therein. Slot 28 preferably is oriented generally at right angles to longitudinal axis “Y”, although it may be oriented differently without departing from the scope of the present invention. Preferably, slot 28 is generally rectangular in shape and is located a short distance inwardly from edge 24 . Aperture 30 is generally D-shaped, is longitudinally aligned and situated adjacent corner 26 . Preferably, one or more notches 31 are defined in corner 26 adjacent aperture 30 and spaced a distance from each other. Front wall 20 a further defines a shoulder 21 which is also generally D-shaped and projects for a distance inwardly into aperture 30 . Preferably, aperture 30 is bounded by a ridge 32 on front wall 20 a that originates in corner 26 proximate left side wall 20 c , extends horizontally for a distance toward right side wall, turns downwardly and extends for a distance toward bottom wall 20 e and then turns again toward left side wall 20 c and extends to corner 26 . Ridge 32 assists in correctly positioning the specially designed magnetic key “K” on a locator 92 that is engaged in aperture 30 , as will be hereinafter described. The correct positioning of the key K″ ensures locking mechanism 16 is able to be disengaged when necessary. [0032] Referring to FIGS. 2A & 3 , inner sleeve 14 comprises a top or end wall 34 a , a bottom or end wall 34 b , a left side wall 34 c , a right side wall 34 d , and a back wall 34 e . An intermediate wall 34 f is disposed between top wall 34 a and bottom wall 34 b . Intermediate wall 34 f is substantially parallel to top and bottom walls 34 a , 34 b and is positioned a short distance above bottom wall 34 b . Top wall 34 a , intermediate wall 34 f , left side wall 34 c , right side wall 34 d and back wall 34 e bound and define a chamber 36 for retaining product “P” therein. Top wall 34 a further includes a peripheral lip 33 ( FIG. 6 ) which is configured to abut shoulder 24 a when sleeve 14 is fully inserted into cavity 22 of jacket 12 . Top wall 34 a further includes front and back edges 35 a , 35 b and a pair of opposed flanges 37 a , 37 b project outwardly from edges 35 a , 35 b . Flanges 37 a , 37 b are configured to be complementary in position, size and shape to notches 25 in upper edge 24 of jacket 12 . When sleeve 14 is locked into jacket 12 , flanges 37 a , 37 b interlockingly engage in notches 25 to effectively prevent lateral motion between jacket 12 and sleeve 14 . [0033] As indicated previously, back wall 34 e of sleeve preferably defines window 38 therein that is elongate and extends longitudinally along back wall 34 e . Window 38 is configured to align with the transparent region of back wall 20 b of jacket 12 , if provided. When security container 10 contains product “P” therein, the product “P” will be visible through the aligned transparent region of back wall 20 a and window 38 . It will be understood that window 38 may be omitted from sleeve 14 and/or back wall 20 b may be non-transparent. In this instance, a product information sheet could be applied to the exterior surface of jacket 12 to indicate the type of product “P” retained within security container 10 . [0034] In accordance with a specific feature of the present invention, a compartment 40 is defined between intermediate wall 34 f , bottom wall 34 b and a front wall portion 42 of sleeve 14 . Compartment 40 is designed to hold the components of the three-way alarm mechanism 18 and all components related to the operation thereof. So, for example, compartment 40 includes components such as a printed circuit board, capacitors, batteries, transistors, and any suitable EAS tag or RFID tag or any other alarm activating or indicating device. It will be understood by those skilled in the art that security container 10 may be provided with a sound generating device that forms part of the alarm mechanism 18 . If that is the case, then a speaker grille (not shown) will be provided in an appropriate location on one or more of the walls of jacket 12 . Security container 10 may also be provided with a LED light to indicate the status of alarm mechanism 18 . As such, a light pipe may be provided on one of the walls of jacket 12 and a LED will be operationally engaged therewith. Although not illustrated herein, it will be understood that alarm mechanism 18 is operationally engaged to locking mechanism 16 by appropriate circuitry. Alarm mechanism 18 will be triggered if an attempt is made to open security container 10 or take security container 10 through a store exit, without deactivating alarm mechanism using the specially designed magnetic key “K”. With respect to sleeve 14 , a rear wall portion (not shown) may also be sonically welled to intermediate and bottom walls 34 f , 34 b of sleeve 14 to seal off access to compartment 40 after the alarm mechanism components have been inserted into the same. The positioning of compartment 40 ensures that a would-be thief cannot access the alarm mechanism components in any way after sleeve 14 is engaged with jacket 12 . [0035] In accordance with another specific feature of the present invention, front wall portion 42 of sleeve 14 is configured to define a depression 44 therein that is shaped to receive a complementary catch 46 . Depression 44 is positioned so that when sleeve 14 is moved within cavity from a first closed position ( FIG. 1 ) to a second open position ( FIG. 11 ), at least a portion of depression 44 will align with slot 28 . [0036] Catch 46 is illustrated in greater detail in FIGS. 2A , 4 , 5 , and 8 . Catch 46 is seated in depression 44 and includes a front surface 46 a which is configured to abut an interior surface of front wall 20 a of jacket 12 and a back surface 46 b which is configured to abut those regions of front wall portion 42 which define depression 44 . Front wall portion 42 of sleeve 14 further defines a generally circular recessed region 48 as part of depression 44 . A coil spring 50 is seated in recessed region 48 and extends therefrom and into an upper recess 56 in back wall 46 b of catch. Spring 50 is biased to urge catch 46 outwardly from depression 44 and toward the interior surface of front wall 20 a of jacket 12 , as will be hereinafter described. A protrusion 52 extends outwardly from a bottom region front wall portion 42 and into depression. Protrusion is complementary to a lower slot 54 ( FIG. 4 ) defined in back surface 46 b of catch 46 . A channel 57 is defined between protrusion 52 and a longitudinally extending region of front wall portion 42 which defines depression 44 . Channel 57 is configured to receive a rounded bottom edge 46 c of catch 46 therein. Channel 57 and bottom edge 46 c are complementary in curvature and bottom edge 46 c is retained within channel 57 in such a manner that bottom edge 46 c pivots within channel 57 about an axis that is disposed at right angles to longitudinal axis “Y”. When catch 46 is positioned in depression 44 , protrusion 52 enters slot 54 and retains catch 46 in depression 44 . [0037] As best seen in FIGS. 2A & 4 , catch 46 includes a tapered projection 58 that extends outwardly from front surface 46 a thereof. Projection 58 is complementary to slot 28 in front wall 20 a of jacket 12 . Since spring 50 is biased to urge the upper region of catch 46 forwardly toward the interior surface of front wall 20 a , when slot 28 aligns with projection 58 when sleeve 14 slides upwardly within cavity 22 of jacket 12 , curved bottom edge 46 c of catch 46 will rotate in channel 57 in the direction “D” and projection 58 will be urged into slot 28 . When this occurs, all longitudinal motion between sleeve 14 and jacket 12 will be substantially prevented and sleeve 14 will be substantially prevented from being completely withdrawn from cavity 22 and disengaging from jacket 12 . Furthermore, until projection 58 is pushed back into cavity 22 to a sufficient degree to cause an outermost tip 58 a of projection 58 to clear the interior surface of front wall 20 a , sleeve 14 and jacket 12 remain in the position shown in FIG. 11 . When projection 58 is pushed inwardly to clear slot 28 , sleeve 14 may be slid in a first direction to disengage it from jacket 12 , or in a second direction to close off access to chamber 36 . [0038] In accordance with yet another feature of the present invention, a hanger member 64 is detachably engageable with an attachment means on one of the sleeve 14 and jacket 12 to enable security container 10 to be hung from a display rod (not shown) in much the same way as a hang tag. In the attached figures, hanger member 64 is shown being detachably securable to an attachment means provided in top wall 34 a of sleeve 14 . It should be understood, however, that the same type of attachment means for hanger member could be provided in bottom wall 20 e of jacket 12 without departing from the scope of the present invention. [0039] Top wall 34 a of sleeve 14 extends between left side wall 34 c , right side wall 34 d and back wall 34 e , and extends for substantially the entire width of left and right side walls 34 c . The attachment means includes a depression 60 ( FIG. 2A ) defined in the exterior surface of top wall 34 a and a recessed wall 61 , which forms the bottom of depression 60 . Recessed wall 61 is spaced a distance inwardly from and parallel to top wall 34 a . A pair of spaced apart, parallel and aligned channels 62 is defined in top wall 34 a and each channel 62 is disposed between one of the side edges of recessed wall 61 and the associated adjacent edge 63 of top wall 34 a . The orientation of channels 62 is at right angles to longitudinal axis “Y” and in a direction extending from front edge 35 a to back edge 35 b of top wall 34 a . (It will be understood that any other orientation of depression 60 and channels 62 may be utilized without departing from the scope of the present invention.) [0040] Hanger member 64 is configured to be selectively engageable with channels 62 . Hanger member 64 includes a generally U-shaped region 66 and a pair of legs 68 that extend downwardly and outwardly from a lower end of the U-shaped region 66 . Hanger member 64 may, instead, comprise a region 66 that is of a different shape, such as a square or a rectangular region, without departing from the scope of the invention. An aperture 70 is defined in region 66 and this aperture 70 is provided so that hanger member 64 may receive a display rod (not shown) therethrough. Each leg 68 of hanger member 64 is generally J-shaped and includes a hooked end having an angled face 68 a and a flat region 68 b . Angled face 68 a enables the hooked end to slide more readily into one of channels 62 . Flat region 68 b is oriented so as to contact the interior surface of top wall 34 a proximate edge 63 when hooked end is received through channel 62 . Hanger 64 further includes a flange member 69 which extends horizontally outwardly from the base of the U-shaped region 66 and is configured to contact an exterior surface of edge region 63 . A gap (unnumbered) is thus defined between flat region 68 b of J-shaped hook and flange member 69 . One or more arcuate grooves 72 are provided in hanger 64 in the region where flange members 69 originate in U-shaped region 66 . Grooves 72 make it possible for legs 68 to be flexed during insertion thereof into channels 62 , and to be flexed when legs 68 are removed therefrom. When hanger 64 is snap-fitted into channels 62 , each edge 63 of top wall 24 a is received in one of the unnumbered gaps between flat region 68 b and flange member 69 . [0041] As indicated previously, security container 10 also contains a locking mechanism 16 . Locking mechanism 16 is of a type similar to that disclosed in U.S. Pat. No. 7,453,370 to Marsilio, the entire disclosure of which is incorporated herein by reference. Specifically, as shown in FIG. 9 , locking mechanism 16 comprises an engagement area 73 provided on left side wall 34 c of sleeve 14 , a spring clip 90 provided on jacket 12 , and a locator 92 provided on an exterior surface of jacket 12 . The engagement area 73 includes two shallow contoured regions 74 , 76 formed into left side wall 34 c , approximately midway between top wall 34 a and intermediate wall 34 f . The shape of the contours is shown in FIGS. 2A , 7 & 9 . A first horizontal ridge 78 is disposed between the first contoured region 74 and the second contoured region 76 . A second horizontal ridge 80 is disposed at the lower end of second contoured region 76 . The interior surface of left side wall 20 c of jacket 12 is provided with a first horizontal slit 82 ( FIG. 10 ) and a second horizontal slit 84 spaced a distance downwardly therefrom. When security container 10 is fully locked (as will be described hereinafter) first slit 82 is generally disposed adjacent an uppermost end of first contoured region 74 and second slit 84 is generally disposed adjacent a lowermost end of second contoured region 76 and proximate second ridge 80 . This is illustrated in FIG. 9 . A first pocket 86 is formed between first contoured region 74 and inner surface of left side wall 20 c and a second pocket 88 is formed between second contoured region 76 and inner surface of left side wall 20 c. [0042] Referring to FIG. 2B and in accordance with a specific feature of the present invention, spring clip 90 is a substantially planar member 90 c manufactured from a magnetic material and includes first and second arms 90 a , 90 b which are spring-biased outwardly out of alignment with the planar member 90 c . Both of jacket 12 and sleeve 14 are manufactured from a nonmetallic material, or may be manufactured from a metallic material that is nonmagnetic. Contoured region 74 includes an inclined face 74 a , a flat face 74 b , and terminates in a horizontal face 78 a . Contoured region 76 includes an inclined face 76 a , a flat face 76 b , and terminates in a horizontal face 80 a . First and second pockets 86 , 88 are complementary sized and shaped to receive first and second arms 90 a , 90 b of spring clip 90 therein when locking mechanism 16 is activated and is moved to a locked position. First and second ridges 78 , 80 are provided to engage the ends first and second arms 90 a , 90 b to arrest the longitudinal movement of sleeve 14 . [0043] Locator 92 is provided to serve two functions. Firstly, locator 92 indicates the location on security container 10 for positioning the magnetic key “K” to move locking mechanism 16 from a locked condition to an unlocked condition. Secondly, locator 92 acts as a guide to keep the sleeve 14 correctly aligned with jacket 12 during sliding motions of the sleeve 14 . This enables sleeve 14 to readily and easily move between a first position where sleeve 14 extends outwardly from cavity 22 and a user is able to access the chamber 36 , and a second position where sleeve 14 is retained within cavity 22 to a sufficient degree that a user is unable to access chamber 36 . It should be noted that when locking mechanism 16 is in the locked condition, alarm mechanism 18 is in an armed condition, and when locking mechanism 16 is in the unlocked condition, alarm mechanism in a non-armed condition. Moving the locking mechanism from the unlocked condition to the locked condition simultaneously moves alarm mechanism 18 from the non-alarmed condition to the alarmed condition. Furthermore, moving the locking mechanism 16 from the locked condition to the unlocked condition simultaneously moves alarm mechanism from the armed condition to the unarmed condition. [0044] Locator 92 comprises an insert that is configured to be received in aperture 30 and to be sonic welded or otherwise secured to front wall 20 a of jacket 12 . Locator 92 includes a generally D-shaped base 98 that is sized to be received in aperture 30 and to abut shoulder 21 of front wall 20 a . A region 98 a of base 98 extends beyond shoulder 21 and terminates substantially flush with an interior surface of front wall 20 a , as is best seen in FIG. 7 . A first guide wall 100 extends outwardly from region 98 a and is disposed generally at right angles thereto. First guide wall 100 is generally rectangular in cross-sectional shape. A second guide wall 102 extends outwardly from region 98 a of base 98 a spaced distance from first guide wall 100 Second guide wall 102 has a truncated triangular shape when viewed in cross-section and, in particular includes an angled surface 102 a so that second guide wall 102 tapers away from base 98 . Both of first and second guide walls 100 , 102 run substantially the entire length of base 98 . A channel 104 is defined between first and second guide walls 100 , 102 and runs substantially the entire length of base 98 . Channel 104 is of a sufficient width to receive a portion of left side wall 34 c of sleeve 14 therein when sleeve and jacket 12 are engaged with each other. Angled surface 102 a on second guide wall 102 is angled in such a manner that channel 104 is wider proximate the outer ends of first and second guide walls 100 , 102 and is narrower proximate base 98 . Angled surface 102 a acts to capture and guide the portion of the left side wall 34 c of sleeve 14 into channel 104 when sleeve 14 and jacket 12 are engaged with each other. [0045] Locator 92 includes two spaced apart indents 94 defined in the outer surface of base 98 and disposed adjacent one side edge thereof. When locator 92 is engaged in aperture 30 , the side edge with the indents 94 is disposed adjacent corner 26 of jacket 12 . When locator 92 is so engaged in aperture 30 , indents 94 align with notches 31 on corner 26 of jacket 12 . Indents 94 are provided to show a store employee where to position the specially designed magnetic key “K” ( FIG. 10 ) in order to disengage the locking mechanism 16 . Indents 94 preferably are D-shaped as they are configured to be complementary to special projections on the key “K”. It will, of course, be understood that any other type or shape of indicator other than indents 94 may be provided on locator 92 of jacket 12 . Additionally, any differently configured locator may be used on jacket 12 instead of the locator 92 . [0046] Referring to FIGS. 9-13 , security container 10 is used in the following manner. Sleeve 14 is inserted into jacket 12 by placing bottom end 14 b thereof into the opening of cavity 22 defined by edge 24 of jacket 12 . Sleeve 14 is oriented so that catch 46 will contact the inner surface of front wall 20 a and will be forced inwardly into depression 44 so that sliding motion is possible between sleeve 14 and jacket 12 . A product “P” is placed into chamber 36 within sleeve 14 . Product “P” is placed on an uppermost surface of intermediate wall 34 f and is oriented thereon so that its display side 106 (such as a side with a logo thereon) faces toward window 38 . [0047] Once product “P” is correctly positioned, sleeve 14 is pushed downwardly in the direction of arrow “A” ( FIG. 11 ) toward bottom wall 20 b of jacket 14 . This downwardly movement causes catch 46 to be moved inwardly toward depression 44 as the angled wall 58 b ( FIG. 4 ) thereon engages the portion of front wall 20 a that defines the bottom end of slot 28 . As catch 46 moves into depression 44 , spring 50 is depressed. As sleeve 14 continues to move downwardly through cavity 22 in the direction of arrow “A”, a portion of left side wall 34 c slides into the upper end of channel 104 in locator 92 . This engagement ensures that locking mechanism 16 will be correctly positioned for unlocking with the key “K” at a future time. Sleeve 14 continues to move downwardly through cavity until bottom wall 36 b of sleeve 14 is disposed adjacent the interior surface of bottom wall 20 c of jacket 12 . At this point, the top 14 a of sleeve 34 a is substantially coplanar with upper edge 24 of jacket 12 , i.e., the exterior surface of top wall 34 a of sleeve 14 is disposed substantially coplanar with upper edge 24 . Flanges 37 on sleeve 14 are received in notches 25 of jacket 12 . [0048] As sleeve 14 and jacket 12 move into this orientation relative to each other, spring arms 90 a , 90 b of spring clip are disposed adjacent to first and second pockets 86 , 88 . Because spring arms 90 a , 90 b are spring biased, when they are adjacent first and second pockets 86 , 88 the spring arms 90 a , 90 b move out of alignment with planar member 90 c and into pockets 86 , 88 and become seated therein. If an attempt is made to move sleeve 14 relative to jacket 12 in a direction opposite to arrow “A”, then the free ends of spring arms 90 a , 90 b will engage the faces of 78 a , 80 a of horizontal members 78 , 80 and thereby substantially prevent further longitudinal movement of sleeve 14 . At this point, locking mechanism 16 is in a locked condition ( FIG. 9 ) [0049] Movement of sleeve 14 from a first position ( FIG. 11 ) to a second position ( FIG. 13 ) and movement of locking mechanism 16 from an unlocked condition to a locked condition also simultaneously closes an electric circuit (not shown) within security container 10 which in turn causes the alarm mechanism 18 to move from an unarmed condition to an armed condition. The wiring of security container 10 has not been shown in the attached drawings to simplify the same, but the wiring of such a device would be within the skill of one of ordinary skill in the art. [0050] Locking mechanism 16 and alarm mechanism 18 can only be deactivated using the specially designed separate magnetic key “K”. The key “K” in question could be substantially identical to the magnetic key described in U.S. Pat. No. 7,453,370 to Marsilio. The key “K” will need to include component parts that are configured to be seated in indents 94 on locator 92 and to thereby bring the magnet(s) “M” in the key “K” into the correct position to influence the magnetic spring arms 90 a , 90 b on spring clip 90 . The magnetic field of the key “K” will cause spring arms 90 a , 90 b to move out of first and second pockets 86 , 88 in the directions of arrow “B” ( FIG. 10 ) and back into alignment with the planar member 90 c of spring clip. When this occurs, the user is able to slide sleeve 14 upwardly in the direction of arrow “C” ( FIG. 12 ), thus sliding sleeve 14 at least partially out of cavity 22 of jacket 12 . The key “K” can be disengaged from locator 92 as soon as spring arms 90 a , 90 b have cleared pockets 86 , 88 . The unlocking of locking mechanism 16 also simultaneously breaks a circuit to alarm mechanism 18 , thus disarming the alarm and moving the alarm mechanism back to an unarmed condition. [0051] Sleeve 14 is able to be moved upwardly until projection 58 on catch reaches slot 28 in front wall 20 a of jacket 12 . When this occurs, the spring 50 moves from the condition shown in FIG. 8 to its original, uncompressed state ( FIG. 12 ) causing catch 46 to rotate on its curved end 46 c within channel 57 . This causes projection 58 to be pushed forwardly and into slot 28 as shown in FIG. 12 . The engagement of projection 58 in slot 28 substantially prevents any further movement in the direction of arrow “C”. Thus, sleeve 14 and jacket 12 remain engaged with each other at all times. [0052] Once the user is able to access chamber 36 within sleeve 14 , the product “P” may be removed therefrom and security container 10 is able to be recycled. Another product (not shown) can be inserted into chamber 36 so that its front surface faces window 38 . The user depresses projection 58 on catch 46 inwardly to remove it from slot 28 and simultaneously pushes sleeve 14 downwardly in the direction of arrow “A” and back into cavity 22 . The movement is continued until locking mechanism 16 moves back into a locked condition and alarm mechanism 18 is re-armed. As indicated previously, if an authorized person attempts to tamper with security container 10 when in this alarmed state or attempts to remove the same from a store without application of the special magnetic key “K”, the alarm mechanism 18 will be activated and will alert store personnel to the tampering or attempted theft incident. [0053] Security container 10 may be suspended from a display rod (not shown) when hanger 64 is snap-fitted into top wall 34 a of sleeve 14 . This is accomplished by inserting hook ends of legs 68 into channels 62 in top wall 34 a of sleeve and pushing downwardly thereon. Inclined surfaces 68 a allow the hook ends of legs 68 to slide readily into one of channels 62 . As inclined surface 68 a engages the side edge of recessed wall 61 , leg 68 is caused to flex inwardly away from wall 61 , allowing the hook end to slide into channel 62 . Once flat region 68 b on leg 68 clears the innermost surface of edge 63 of top wall 34 a , leg 68 returns to its original position and snaps into abutting contact with side edges of recessed wall 61 , locking hanger member 64 into engagement therewith. The display rod may then be inserted through aperture 70 . [0054] It will be understood that hanger member 64 may be omitted from security container 10 or may be detached therefrom. In order to detach hanger member 64 from its engagement with security container 10 , a store employee engages outer side edges of flanges 69 and then pinches them toward each other. This movement causes hanger member 64 to flex at grooves 72 , moving legs 68 to a position where the hooked ends will disengage from edges 63 of top wall 20 a . Legs 68 may then be withdrawn from channels 62 , thus disengaging hanger member 64 from sleeve 14 . Security container 10 is then able to be positioned on a display shelf (not shown) and may do so resting on any of the jacket's exterior walls or even on top wall 20 a of sleeve 14 . The two channels 62 pose no risk for entry into chamber 36 to access product “P” as they are simply too small. A would-be thief also cannot disarm the alarm mechanism 18 through channels 62 as this mechanism 18 is situated on the opposite end of sleeve 14 from channels 62 . [0055] Referring to FIGS. 13-16 there is shown a second embodiment of the security container in accordance with the present invention, generally indicated at 110 . One feature that is different about security container 110 with respect to container 10 is that this second embodiment is adjustable in overall length. Security container 10 is of a length “L” ( FIG. 1 ) that is substantially equal to the length of jacket 12 . Security container 110 , on the other hand, is of a minimum length “L” and may be adjusted to a maximum length equal to the length “L”+“L1” shown in FIG. 16 . Neither of the lengths “L” nor “L1” include the height of the hanger member 64 , 164 . [0056] Security container 110 is comprised of an outer jacket 112 and an inner sleeve 114 . Jacket 112 includes a front wall 120 a , a back wall 120 b , a left side wall 120 c , a right side wall 120 c , and a bottom wall 120 e . The front, back, left side, right side and bottom walls bound and define a cavity 122 ( FIG. 14 ) into which sleeve 114 is longitudinally, slidably received in much the same manner as jacket 12 and sleeve 14 . Jacket 112 is substantially identical to jacket 112 except for a few features. Firstly, the structure of locking mechanism 116 and the location of the same on security container 110 differs from locking mechanism 16 and its location on security container 10 . In jacket 12 , shown in FIG. 1 , the locking mechanism 16 is positioned beneath a plate 17 located adjacent corner 26 of jacket 12 . In jacket 112 , shown in FIG. 13 , the locking mechanism 116 is positioned beneath a plate 117 located roughly midway between corners 126 and 127 on left side wall 120 c of jacket 112 . During manufacture an aperture may be formed in left side wall 134 c of jacket 112 and spring clip 190 be secured to plate 117 which is then sonic welded into the aperture so that spring arms 190 a , 190 b project into cavity 122 . Spring clip 190 ( FIG. 14 ) forms part of locking mechanism 116 and is secured to the interior surface of left side wall 120 c of jacket 114 . Spring clip 190 is substantially identical to spring clip 90 except that each of its first arm 190 a and second arm 190 (which are movable relative to the planar member thereof) terminates in a hook 191 a , 191 b instead of simply being straight. The purpose of the hooks 191 a , 191 b will be described hereafter. [0057] Sleeve 114 differs from sleeve 14 in a number of ways. Firstly, as shown in FIG. 16 , sleeve 114 has a top wall 134 a , a back wall 134 b , a left side wall 134 c , and a right side wall 134 d . Sleeve 114 also has a front wall 134 e and, even though it is not shown in the attached figures, sleeve 114 does not have a bottom wall. Furthermore, sleeve 114 does not have an intermediate wall and a compartment which houses all of the security components. Preferably, the intermediate wall and the compartment which houses all of the security components are identical to wall 34 f and compartment 40 of sleeve 14 but are located in the interior bottom end of jacket 112 above the interior surface of bottom wall 20 b . Still further, a recessed region (not shown) is defined in front wall 134 e of sleeve 114 proximate a bottom end thereof. The recessed region defines a depression in which catch 146 is engaged. Each of the recessed region, the depression and the catch 146 are substantially identical in structure and function to recessed region 44 , 52 , 48 and catch 46 on security container 10 . Catch 146 is engageable in slot 128 in front wall 134 a of jacket 112 to keep sleeve 114 from being disengaged from jacket 112 unless and until it is desirable to do so. [0058] In accordance with a specific feature of the present invention, locking mechanism 116 further includes a rack 115 which is provided on an exterior surface of left side wall 134 c of sleeve 114 . Rack 115 is configured to be engageable with spring clip 190 . Preferably, rack 115 extends longitudinally generally along a midline of left side wall 134 c . This location makes the operation of locking mechanism 116 more stable than if the rack 115 is situated adjacent one or the other corners 126 , 127 . Rack 115 and spring clip 190 are positioned in complementary locations on jacket 112 and sleeve 114 . As best seen in FIG. 15 , rack 115 includes a plurality of horizontally oriented teeth 118 thereon. Adjacent teeth 118 are separated from each other by a trough 119 . As is evident from FIG. 15 , hooked ends 191 a , 191 b of spring clip 190 are selectively engageable in any one of the plurality of troughs 119 on rack 115 . Each tooth 118 has an angled face 119 a and a straight face 119 b . The orientation of the straight faces 119 b and the angled faces 119 a is such that movement of the sleeve 114 in the direction downward direction to reduce the size of security container 110 is relatively easy. Teeth 118 substantially prevent upward movement to increase the length of security container without first moving hooked ends 191 a , 191 b of spring clip 190 out of troughs 119 . The teeth 118 thereby lock sleeve 114 to jacket 112 to prevent sleeve 114 from being withdrawn from cavity 112 to access the product. When it is desired to detach sleeve 114 from jacket 12 , teeth 118 must be withdrawn from the troughs 119 . This is accomplished by engaging the specially configured magnetic key “K” (shown in FIG. 10 ) in the indents 194 on locator 192 . Locator 192 functions in the same manner as locator 92 in security container 10 . Once the tips of hooked ends 191 a , 191 b of spring clip 190 clear the outermost ends of teeth 118 , sleeve 114 may be slid longitudinally relative to jacket 112 in either direction, as is indicated by arrow “E” ( FIG. 16 ). It will be understood that locator 192 may be positioned in any other location on security container 110 that will enable the specially designed magnetic key “K” to attract the magnetic spring arms 190 a , 190 b of spring clip 190 out of the troughs 119 of rack 115 , without departing from the scope of the present invention. Locator 192 may be configured to be substantially identical to locator 92 where it acts both to guide the travel of sleeve 14 relative to jacket 12 . Alternatively, locator 192 may simply be a planar component that is secured to the exterior surface of jacket 114 in an appropriate location such that the indents 194 thereon are correctly positioned to align the magnets “M” in key “K” with spring arms 190 a , 190 b of spring clip 190 . [0059] Security container 110 is used in the following manner. Initially, it is necessary to access to the chamber 136 ( FIG. 14 ) in order to insert a product into the same. Since sleeve 114 includes top, back, front, left and right side walls 134 a - 134 e it is necessary to completely detach sleeve 114 from jacket 112 . In order to do this, the projection (not numbered but the equivalent of projection 58 on catch 46 ) is pushed inwardly through slot 128 so that it moves back toward the interior of security container 110 . Once the projection is clear of slot 128 , sleeve 11 is pulled upwardly to separate sleeve 114 from jacket 112 . A product (not shown) is then inserted into cavity 122 of jacket 112 and sleeve is engaged with jacket 112 to enclose the product within the interior formed by cavity 122 and chamber 136 . Sleeve 114 is slid longitudinally into cavity 122 to a sufficient degree that at least the catch 146 engages in slot 128 . Catch 146 is then disengaged once again from slot 128 and sleeve 114 is moved inwardly until the interior surface of recessed wall 161 ( FIG. 14 ) is disposed adjacent a top end of the product. Hanger member 164 may be engaged with sleeve 114 or may be omitted from security container 110 as was described with reference to hanger member 64 and security container 10 . As with security container 10 , security container 110 may include a number of transparent walls in jacket 112 and sleeve 114 so the product may be seen by the consumer. [0060] A third embodiment of the present invention is contemplated but not illustrated herein. In this third embodiment, the security container is substantially identical to security container 10 but includes the placement of the locking mechanism in a location substantially identical to that of security container 110 . The sleeve and jacket of this third embodiment are substantially identical to the sleeve 14 and jacket 12 , with the exception that the window in the sleeve of the third embodiment is substantially smaller than the window 38 . In particular, the window in the third embodiment originates a greater distance away from the top wall of the sleeve. This increased distance is specifically selected so that it is impossible to gain access into the interior chamber of the sleeve of this third embodiment security container when the locking mechanism is utilized to increase the overall length of the combined sleeve and jacket. All other components are substantially identical in structure and function to those particular components in one or both of security containers 10 , 110 . [0061] In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. [0062] Moreover, the description and illustration of the invention are an example and the invention is not limited to the exact details shown or described.
A security container for holding a product. The container includes a jacket having a cavity, a sleeve receivable in the cavity, and a chamber in the sleeve for holding the product. The sleeve moves within the cavity between a position where a user can access the chamber and a position where they cannot access the chamber. A locking mechanism secures the sleeve against movement when in the locked condition and permits movement thereof when unlocked. An alarm mechanism is provided that is simultaneously activated when the locking mechanism is locked and deactivated when the locking mechanism is unlocked. The locking mechanism includes a magnetic locking member movable by a dedicated magnetic key to unlock the mechanism. The security container is adjustable in length to accommodate products of different sizes. The container is of a diminutive size in that it is capable of fitting into a man's dress shirt pocket.
4
BACKGROUND OF THE INVENTION The present invention relates to cutting devices, particularly, a relatively high speed cutter to be used on a moving web. In the past, traveling webs have been cut at a station in which web travel has been halted. A knife blade acting against a supporting edge moves in a generally vertical path with respect to a horizontally moving web. The blade may be angled so that as the blade moves in the vertical direction, the area of intersection of the blade with the backing plate appears to translate in a direction transverse to the direction of web travel. This angled cutting, which can be found in most paper cutters, and for example, the guillotine, only cuts a small increment of the web at any given time in the travel of the blade. Accordingly, less cutting force is required. An alternative cutting device for use with a moving web also uses a "travelling" cutting edge. A matched pair of rollers are positioned with their axes transverse to the path of the web. One of the rollers has a blade that is embedded in the roller. The opposing roller may have either a matching plate or may be of a resilient material that deforms under the blade. As the roller rotates, the knife edge effectively traverses the width of the web. Since the web is moving, the rollers may be angled slightly in the direction of web travel so that cut will be at right angles to the web edge. Such a device must be provided with some mechanism that permits it to "idle" or remain out of engagement with the web until the web is to be cut into the desired length. This may require bringing one or both rollers in and out of engagement with the web. Other approaches may require that the rollers be provided with clutches that can be selectively engaged when a cut is required. Further, prior art web cutting systems required blades which came to a sharp cutting edge with either a single or double taper. Such blades quickly dull and are dangerous to handle. Further, such blades present a substantial hazard to workers because of the sharpness of the cutting edge. Scissors or shears rely on relatively thicker blades with a substantially right angled edge. The blades are joined at a pivot point and are mounted to be intersecting at a shallow angle. Because of the flexibility of the blades, the point of intersection travels outward from the pivot point with the blades displacing each other sufficiently to allow a cutting intersection to travel to the free ends of the blades. It would be desirable to adapt the "scissors-type" cutting action of shears to the problem of cutting a traveling web. In fact, if a flexible web is driven to the cutter and the cutting action is rapid enough, the web can be momentarily halted while the cutter is employed. The cut section can be removed and the web can then continue until another cut is commanded. SUMMARY OF THE INVENTION According to the present invention, a high speed, novel web cutter is provided at the output end of a printer or other device which operates in conjunction with a moving web. The web may be paper, plastic or fabric and may even include metallic foils. In a preferred embodiment, the web is paper. A roller with an extended bar having a right or acute angled edge extending in the axial direction cooperates with a plate having a right or acute angled edge that is mounted on a relatively stiff, cantilever spring. Both edges are in planes that are not parallel with the plane of the web but are at a predetermined angle with respect to the plane of the web. When the roller is rotated, one end of the roller mounted bar edge overlaps the plate slightly. The roller mounted bar edge engages the plate and depresses the plate against the spring until the roller edge "clears" the plate edge. The angled orientation of the plate and roller edges creates a traveling point of intersection as the roller continues to rotate at a relatively high rate of rotation. A web that is between the roller and the plate is rapidly cut by the moving intersection of the edges. When the roller edge completely clears the plate edge, the roller is free to rotate to an initial, rest position. The circumferential velocity of the roller is much greater than the speed of web travel. Accordingly, it is an object of the invention to provide an improved web cutter that can be operated selectively to provide cut pages of variable length. It is a further object of invention to provide a high speed web cutter that can operate with a moving web. It is an additional object of the invention to have a web cutter that utilizes a scissor action with a moving point of intersection. The novel features which are characteristic of the invention, both as to structure and method of operation thereof, together with further objects and advantages thereof, will be understood from the following description, considered in connection with the accompanying drawings, in which the preferred embodiment of the invention is illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only, and they are not intended as a definition of the limits of the invention. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a top view of a web cutter embodying the present invention; FIG. 2 is an elevational view of the web cutter of FIG. 1 taken along line 2--2 in FIG. 1 in the direction of the appended arrows; FIG. 3 is a cross-sectional view of the invention of FIG. 1, taken along line 3--3 in FIG. 1 in the direction of the appended arrows, with a web of material and a web guide; FIG. 4 is the same cross-sectional view as FIG. 3 except that the web material has not been cut; and FIG. 5 is an elevational view of the invention without a side frame and latching mechanism, the invention in its open position being drawn in phantom. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIGS. 1 through 4 illustrate the general appearance of a web cutter as constructed in accordance with the invention disclosed and claimed herein. A preferred embodiment of the invention in the form of a paper cutter 10 as illustrated in FIG. 1, is preferably constructed of metal to be sufficiently durable for the cutting of paper or other web material at high speed. Other web materials such as thin film plastics, fabrics or metal foils may also be used with the present invention. Cutter 10 in the preferred embodiment has a frame 12 forming the base of the device. Frame 12 has a driven end 14 and an opposite end 16. Each of the ends of frame 12 contains a bearing, 18 and 20 respectively, for supporting each end of a roller 22. Roller 22 extends between the opposite ends 14, 16. At the driven end 14, roller 22 has an axial extension that protrudes through the bearing and beyond end 14 in order to receive a pulley 24 which is driven by a motor, not shown. A cutting bar 26 is detachably mounted on roller 22 and extends between the opposite end 16 and the driven end 14. It should be noted that cutting bar 26 is not centrally aligned to the longitudinal axis of roller 22. Rather, it is skewed slightly to the right with respect to the longitudinal axis as shown in FIG. 1. Cutting bar 26 has a cutting edge 28 (best seen in FIGS. 3 and 4) which may be sharpened easily due to the fact that bar edge is detachably mounted on roller 22. Illustrated in FIGS. 1 through 4 is a plate 30 which has a stationary edge 32 (best seen in FIGS. 3 and 4) which is positioned so as to operate cooperatively with cutting edge 28. Plate 30 is detachably mounted on a suitably stiff cantilever spring 40 which is mounted on a support 42 by means of fasteners 44 (best seen in FIG. 2). As can be seen in FIGS. 3 and 4, plate edge 30 is located just below the plane of a traveling web material to be cut. When a continuous web 50 of material is fed over the stationary edge 32, the web material is allowed to pass beneath the roller 22 and then over a block 110 as shown in FIG. 4. It is important to understand the relative position of stationary edge 32 to cutting bar 26 and cutting edge 28. As can be seen in FIG. 2, they are not parallel to one another. FIG. 2 shows that the portion of stationary edge 32, near the opposite end 16, is farther from cutting bar 26 than is at driven end 14. This non-parallel relationship, when combined with the traverse mounting of cutting bar 26 on roller 22, causes cutting edge 28 to first contact that portion of stationary edge 32 near driven end 14 during each rotational cycle of the roller 22. When the cutting edge 28 engages the stationary edge 32, it will cause the cantilever spring 40 to deflect downward in the region of driven end 14. This downward deflection will cause the end of the cutting edge 28 to slip past the stationary edge 32. Because of the non-parallel relationship between cutting edge 28 and stationary edge 32, the point of contact moves across plate 30 from the driven end 14 to the opposite end 16. As the point of contact or interference moves across the plate 30, it will encounter the continuous web 50 which is severed by the scissors like action. Referring now to FIGS. 3 and 4, continuous web 50 is fed between a drive roller 104 and a pinch roller 106. When the web 50 reaches cutting edge 32, it is in position to be cut. Due to the fact that cutting bar 26 begins to cut continuous web 50 near the driven end 14, the portion of the continuous web 50 that is not yet severed will tend to buckle upward slightly. This condition is only momentary and will cease once the cut is completed. In order to ensure an accurate cut, a plate 108 has been provided to control and limit this buckling action. Once continuous web 50 has traveled beneath roller 22 it slides between a guide 109 and a block 110. FIG. 4 illustrates the position of roller 22, prior to a severing of the continuous web 50. As shown in FIG. 3, the cut portion of the continuous web 50 is a document of desired length. In operation, the roller 22 makes one rotation per cut of the continuous web 50. It begins at a ready position, as shown in FIG. 4 and then makes one complete revolution per cut, coming back to a ready position. The intermediate position, just after a cut is shown in FIG. 3 which, in the preferred embodiment, is reached after a shaft rotation of less than 60°. However, the rotation of the roller 22 may be made continuous, that is, the roller 22 need not stop at any point in its rotation if very short documents are required. The roller 22 may also be made to come to stops of varying duration during each cycle, so that it is possible to cut the continuous web 50 into sheets of various desired lengths. Referring now to FIG. 5, cutter 10 is depicted in its preferred embodiment, which is comprised of two main assemblies, a chassis 100 and a hinged door 150. Door 150 is hinged at its bottom edge so that it swings outward and down for facilitating web loading. For purposes of illustration the side panels of chassis 100 and door 150, along with a latching means, have been omitted from FIG. 5. In the preferred embodiment of the invention, cutter 10 is located at the top or output end of a larger apparatus, such as a high speed printer. The printing function has not been illustrated in that it is not necessary to this invention. FIG. 5 depicts the paper cutter assembly in two different positions, a closed position and (depicted in phantom) an open position. The open position is used to ease the loading of web material through the apparatus. In order to load a continuous web material, hinged door 150 is unlatched and moved away from chassis 100, as shown by the phantom lines in FIG. 5. Web material 50 is then pulled upward above the top of the cutter 10. The hinged door 150 is then closed and latched. The web material is then automatically positioned for the cutting operation. Chassis 100 has a frame 102 which is constructed of a durable, preferably metal material and is formed integrally with a printer frame (not shown). As is illustrated in FIG. 5, web 50 is driven vertically by a drive roller 104 and a pinch roller 106. As the web 50 moves upward, it passes along adjacent to guide 108 and then continues between rotating cutting bar 26 and stationary edge 32 of plate 30. As illustrated in FIGS. 3, 4 and 5, web material 50 is moving through paper cutter 10, cutting bar 26 is not rotating, but is located at a ready position, out of the path of web material 50. At the appropriate time, cutting bar 26 will make one revolution and sever web material 50 by making a cut across web material 50, in a direction that is perpendicular to the travel path of the web. The cutting action requires less than 60 ° of rotation. Rotating cutting bar 26 will then return to its ready position out of the path of web material 50. If the printer cutter is being operated at high speed, this cutting cycle may occur several times per second. Once web material 50 has moved past the cutting bar 26, it is directed out of the cutter 10 by a deflecting guide 109 and a block 110. The path of web material 50 at this point is clearly illustrated in FIG. 4. Severed documents may be collected by an operator or accumulated in a bin for later processing. Even though numerous characteristics and advantages of the invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of the parts, within the principles of the invention. Accordingly, the scope of the invention should be limited only by the breadth of the claims appended hereto.
A high speed web cutter has a rotating roller with an extended bar mounted perpendicular to its surface and angled to be aligned askew with respect to the roller's axis. During the rotation of the roller, the bar interferingly contacts a plate having an angled edge that is mounted on a relatively stiff cantilever spring. The bar edge and the plate edge are not mounted parallel with each other nor are either of them parallel with the plane of the web. As the roller rotates, the extended bar deflects the cantilever spring, allowing the edges to intersect in a cutting intersection that travels axially with roller rotation, thereby severing a web member passing between the roller and the plate edge.
1
BACKGROUND OF THE INVENTION [0001] This application claims the priority of Korean Patent Application No. 2003-3667, filed on Jan. 20, 2003, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference. [0002] 1. Field of the Invention [0003] The present invention relates to an optical switch using a micro-electromechanical system (MEMS), and more particularly, to a 2×2 way optical switch. [0004] 2. Description of the Related Art [0005] U.S. Pat. Nos. 6,303,885, 6,315,462, and 6,229,640 disclose techniques for a 2×2 way optical switch used in various optical applications. Optical switches disclosed in U.S. Pat. Nos. 6,229,640 and 6,315,462 have a structure in which a mirror is driven by an electro-static comb drive and the optical switch disclosed in U.S. Pat. No. 6,303,885 has a structure in which a mirror is driven by spring arms. The structures of the optical switches have a common feature in that the mirror moves in parallel with the plane of a substrate by an actuator. [0006] [0006]FIG. 1 is a microscopic photo of a conventional 2×2 comb drive optical switch having two inputs and two outputs, and FIG. 2 is a plane view of a portion marked with dotted lines in FIG. 1 to explain the conventional 2×2 comb drive optical switch shown in FIG. 1. [0007] As shown in FIGS. 1 and 2, first and second optical input fibers 2 a and 2 b , and first and second optical output fibers 3 a and 3 b are arranged at around the central point P at an angle of 90 degrees. A mirror 1 is positioned at the central point P of the first and second optical input and output fibers 2 a , 2 b , 3 a , and 3 b. [0008] As shown in FIG. 3, when the mirror 1 is positioned out of the central point P, optical signals incident through the first and second input fibers 2 a and 2 b proceed toward the first and second output fibers 3 a and 3 b on the same axes with the first and second input fibers 2 a and 2 b without being reflected. [0009] As can be seen in FIG. 4, when the mirror 1 is positioned at the central point P, an optical signal incident through the first input fiber 2 a is reflected from one side of the mirror 1 and then proceeds toward the second output fiber 3 b , and an optical signal incident through the second input fiber 2 b is reflected from the other side of the mirror 1 and then proceeds toward the first output fiber 3 a. [0010] Here, as shown in FIG. 4, when an optical signal is reflected by a mirror, the optical signal is reflected out of the central point of the mirror. Thus, the reflected optical signal does not proceed toward the central point of a target fiber. This is caused by an offset of an optical path due to the thickness of the mirror. [0011] The offset causes light loss. The thicker the mirror, the greater the offset, which increases light loss. Accordingly, the thickness of the mirror is required to be reduced as it can be in order to reduce the offset of an optical path changed by the mirror. However, since in the above-described comb drive optical switch, the mirror moves in parallel with the plane of the substrate and a reflective surface of the mirror is perpendicular to the plane of the substrate, there is a limitation in reducing the thickness of the mirror. In particular, when forming a mirror, silicon is vertically etched in a plasma process, and then a metal having a high reflectance is deposited on the surface of the resultant structure. Thus, it is difficult to reduce the thickness of the mirror. Also, since the vertically etched surface is used as a reflective surface, a large amount of light is lost when light is reflected. Furthermore, since a high-priced silicon on insulator (SOI) wafer not a general wafer is used, cost for manufacturing the mirror is high. SUMMARY OF THE INVENTION [0012] The present invention provides an optical switch capable of reducing an offset of an optical path by reducing the thickness of a mirror. [0013] The present invention also provides an optical switch which can cause a small amount of light loss and be manufactured at a low cost. [0014] According to an aspect of the present invention, there is provided an optical switch including a substrate, a first input fiber and a first output fiber, a second input fiber and a second output fiber, a rotating mirror, torsion bars, and an electrostatic force generating part. The first input fiber and a first output fiber are arranged at a predetermined distance from a central point in a first optical path passing through the central point over the substrate. The second input fiber and a second output fiber are arranged at a predetermined distance from the central point in a second optical path that passes through the central point and is orthogonal to the first optical path. The rotating mirror is positioned at around the central point and turns on a turning shaft extending in parallel with the substrate. The torsion bars support the rotating mirror so that the rotating mirror rotates. The electrostatic force generating part supplies a drive force to the rotating mirror. [0015] In an aspect of the invention, trenches into which the first and second input fibers and the first and second output fibers are inserted are formed in the substrate along the first and second optical paths. [0016] In an exemplary embodiment of the invention, the rotating mirror has a first position where the rotating mirror is parallel with the substrate and a second position where the rotating mirror is perpendicular to the substrate, and turns from the first position to the second position by the electrostatic force generating part. BRIEF DESCRIPTION OF THE DRAWINGS [0017] The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which: [0018] [0018]FIG. 1 is microscopic photo of a conventional optical switch including a mirror perpendicular to a substrate; [0019] [0019]FIGS. 2 through 4 are views for illustrating an optical path changed by the conventional optical switch shown in FIG. 1; [0020] [0020]FIG. 5 is a schematic plane view of an optical switch according to the present invention; [0021] [0021]FIG. 6 is a perspective view of a mirror and a mirror driving actuator used in the optical switch according to the present invention; [0022] [0022]FIG. 7 is a schematic cross-sectional view of the mirror driving actuator shown in FIG. 6; [0023] [0023]FIG. 8 is a cross-sectional view taken along line I-I of in FIG. 5; [0024] [0024]FIG. 9A is a cross-sectional view of a trench into which an optical fiber is fixed, in the optical switch, according to the present invention, shown in FIG. 5; [0025] [0025]FIG. 9B is a plan view of a spring formed in an opening of a trench into which an optical fiber is fixed in the optical switch according to an exemplary embodiment of the present invention; [0026] [0026]FIG. 10 is a schematic cross-sectional view for explaining a process of inserting an optical fiber into a trench in the optical switch according to the present invention; [0027] [0027]FIGS. 11A and 11B are views for explaining the operation of the optical switch according to the present invention; and [0028] [0028]FIGS. 12A through 16B are cross-sectional views for explaining a method of manufacturing the optical switch according to the present invention. DETAILED DESCRIPTION OF THE INVENTION [0029] Hereinafter, an optical switch according to an exemplary embodiment of the present invention will be described in detail with reference to the attached drawings. [0030] As shown in FIG. 5, optical input fibers 20 a and 20 b , and optical output fibers 30 a and 30 b are arranged at around the central point P at an angle of about 90 degrees. A rotating mirror 10 is positioned at the central point P. As in a general optical switch, the optical input fibers 20 a and 20 b , and the optical output fibers 30 a and 30 b are inserted into trenches 41 formed in a substrate 40 . The trenches 41 are arranged at around or at about the central point P at an angle of about 90°. As shown in FIG. 6, the rotating mirror 10 is fixed to posts 42 formed on the substrate 40 and supported by torsion bars 43 that extend from the posts 42 in parallel with the substrate 40 . The torsion bars 43 support the rotating mirror 10 so that the rotating mirror 10 is parallel with the substrate 40 . When the rotating mirror 10 turns due to an electrostatic force, the torsion bars 43 provide a returning force to the rotating mirror 10 so that the rotating mirror 10 returns to the original position. The torsion bars 43 extend toward a turning axis X-X at an angle of approximately 45 degrees with the optical input fibers 20 a and 20 b and the optical output fibers 30 a and 30 b . A well 45 is formed under the rotating mirror 10 . The well 45 has a rectangular shape and a vertical sidewall 44 contacting one side of the rotating mirror 10 when the rotating mirror 10 turns due to an electrostatic force. [0031] [0031]FIG. 7 shows the cross-section of the well 45 and the rotating mirror 10 . Referring to FIG. 7, a fixed electrode 46 , which is opposite to the rotating mirror 10 when the rotating mirror 10 faces the vertical sidewall 44 , is formed on the vertical sidewall 44 . The fixed electrode 46 extends to the bottom of the well 45 . A dielectric or insulating layer 47 , which serves to prevent the direct contact of the rotating mirror 10 with the fixed electrode 46 , is formed on the fixed electrode 46 . The rotating mirror 10 is formed of a conductive material, e.g., a metal thin film, and has reflective surfaces on either side thereof. Thus, when the rotating mirror 10 is substantially parallel with the substrate 40 as indicated by “A”, the rotating mirror 10 passes a beam so as to optically connect the fibers facing on the same axis, and when the rotating mirror 10 is substantially perpendicular to the substrate 40 as indicated by “B”, the rotating mirror 10 reflects an incident beam so as to change the optical path of the incident beam. According to an exemplary embodiment of the present invention, an anti-electrostatic electrode 48 , which maintains the same potential as the rotating mirror 10 , is formed under the rotating mirror 10 and on an opposite side of the well 45 centering at around the posts 42 . This is to prevent an electrostatic force from being generated between the rotating mirror 10 and the vertical sidewall 44 of the well 45 so that an attractive force is generated only in the well 45 due to the electrostatic force. [0032] [0032]FIG. 8 is a cross-sectional view taken along line I-I of FIG. 5. Referring to FIG. 8, an insulating layer 49 is formed at around the central area in which the rotating mirror 10 is positioned. A metal layer 50 is formed on the insulating layer 49 . The metal layer 50 is formed from the same material the rotating mirror 10 is formed from, at the same time, and then separated from the rotating mirror 10 during a patterning process of a process of manufacturing the rotating mirror 10 . The insulating layer 49 is a sacrificial layer necessary for forming the rotating mirror 10 and the posts 42 , serves as a layer on which a metal thin film is deposited to form the rotating mirror 10 , and is locally removed after completing the rotating mirror 10 . [0033] [0033]FIG. 9A is a cross-sectional view showing the internal structure of the trenches to which the optical input fibers 20 a and 20 b and the output fibers 30 a and 30 b are fixed. Referring to FIG. 9, a portion of the insulating layer 49 and a portion of the substrate 40 are etched to form the trenches 41 into which the optical input fibers 20 a and 20 b and the output fibers 30 a and 30 b are inserted. Openings of the trenches 41 are narrowed by the metal layer 50 . Here, a spring 51 of the metal layer 50 restrains the optical input fibers 20 a and 20 b and the optical output fibers 30 a and 30 b from separating from the trenches 41 . Referring to FIG. 9B, the spring 51 may be further flexibly comb-shaped. As shown in FIG. 10, the spring 51 elastically deforms so that the optical input fibers 20 a and 20 b and the optical output fibers 30 a and 30 b engage the trenches 41 . Channels 41 a are formed to a width smaller than the diameter of the optical input fibers 20 a and 20 b and the optical output fibers 30 a and 30 b in the trenches 41 and in the surface of the substrate 40 . The channels 41 a support the optical input fibers 20 a and 20 b and the optical output fibers 30 a and 30 b and determine the positions of the optical input fibers 20 a and 20 b and the optical output fibers 30 a and 30 b. [0034] [0034]FIGS. 11A and 11B are views for explaining an optically switching state by the rotating mirror 10 . FIG. 11A shows that an electrostatic force is not applied to the rotating mirror 10 , i.e., the rotating mirror 10 is parallel with the substrate 40 as indicated by “A” in FIG. 7. In this state, beams incident through the optical input fibers 20 a and 20 b proceed toward the optical output fibers 30 a and 30 b on the same axes as the optical input fibers 20 a and 20 b , respectively. FIG. 11B shows that an electrostatic force is applied to the rotating mirror 10 , i.e., the rotating mirror 10 is substantially perpendicular to the substrate 40 as indicated by “B” in FIG. 7. In this state, beams incident through the optical input fibers 20 a and 20 b are reflected from the rotating mirror 10 and then proceed toward the optical output fibers 30 b and 30 a on the different axes from the optical input fibers 20 a and 20 b , respectively. [0035] As described above, an optical switch according to the present invention is a 2×2 optical switch in which a moveable electrostatic actuator and optical fibers are combined. The optical switch has a structure in which a mirror and the fibers are arranged by a trench structure having a spring. [0036] A process of manufacturing the optical switch of the present invention having the above-described structure will be described in brief with reference to FIGS. 12A through 16B. This process corresponds to a well-known MEMS process, and thus steps of forming detail structures will be briefly explained herein. FIGS. 12A, 13A, 14 A, 15 A, and 16 A are cross-sectional views for showing a mirror and a well thereunder, and FIGS. 12B, 13B, 14 B, 15 B, and 16 B are cross-sectional views for showing trenches. [0037] [0037]FIGS. 12A and 12B, a well 45 having a vertical sidewall 45 a and a channel 41 a constituting a lower part of the trench 41 into which a fiber is inserted are formed in a silicon wafer or a glass substrate 40 . A metal layer is deposited and then patterned to form a fixed electrode 46 and an anti-electrostatic electrode 48 . [0038] As shown FIGS. 13A and 13B, an insulating layer 47 is formed on the entire surface of the glass substrate 40 . [0039] As shown in FIGS. 14A and 14B, a film 49 made of an insulator is laminated on the insulating layer 47 on the glass substrate 40 . [0040] As shown in FIGS. 15A and 15B, a metal layer 50 is deposited on the film 49 and then patterned to form a mirror 10 opposite to the well 45 and a spring 51 that is positioned over the channel 41 a. [0041] As shown in FIG. 6, structures for supporting the mirror 10 and fibers are completed using a dry etching process. [0042] As described above, in an optical switch according to the present invention, a mirror can turn at an angle of approximately 90 degrees, which results in adjusting optical paths. In other words, the optical switch according to the present invention can be switched by a moveable actuator having a simple structure without using a comb drive linear actuator having a complicated structure. Here, the thickness of the mirror is determined when depositing a metal layer. In other words, since the metal layer can be deposited to a thickness of hundreds of Å, the thickness of the mirror can be drastically reduced. The reduction in the thickness of the mirror means that the light loss due to an offset in a conventional optical switch can be almost eliminated. Also, since the deposited metal layer is used as the mirror, light loss caused by the roughness of the mirror can greatly be reduced. [0043] The optical switch according to the present invention can be manufactured using a general wafer unlike existing methods to manufacture switches from an SOI wafer. Thus, the optical switch can be manufactured according to a simple unit process, resulting in a great reduction in cost for manufacturing the optical switch. [0044] While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims.
Provided is a 2×2 optical switch includes a substrate, a first input fiber and a first output fiber, a second input fiber and a second output fiber, a rotating mirror, torsion bars, and an electrostatic force generating part. The first input fiber and a first output fiber are arranged at a predetermined distance from a central point in a first optical path passing through the central point over the substrate. The second input fiber and a second output fiber are arranged at a predetermined distance from the central point in a second optical path that passes through the central point and is orthogonal to the first optical path. The rotating mirror is positioned at around the central point and turns on a turning shaft. The torsion bars support the rotating mirror and the electrostatic force generating part supplies a drive force to the rotating mirror.
6
BACKGROUND OF THE INVENTION This invention relates in general to certain new and useful improvements in doll heads providing nodding movement and a turning movement to signify respective "yes" and "no" answers on a random basis, and, more particularly, to movable doll heads of the type stated which provide nodding and turning movements on a random basis through an independently actuable camming mechanism. Doll heads having two randomly selected movements are known in the art, as for example, one such doll head is taught in U.S. Pat. No. 3,456,950. These doll heads are useful play devices, primarily for children, since they can provide yes and no responsive movements on a random basis, and can be used either alone, as a type of fortune-telling device, or in conjunction with the playing of different types of games in which yes and no decisions are made. It can be appreciated that the value of this type of doll head to children would be depreciated if the selection was made on any other than a random basis, since one response would be provided more often than the other of the responses. In addition to the above, it can be observed that this form of device could also find use as an "adult's toy", as for example, a so-called "executive" decision maker. One of the primary problems with doll heads providing randomly selected responses of this type is that in order to obtain true random selection of a response, the device is usually complicated in its structure and, hence, fairly costly to manufacture. Moreover, and also due to the necessity of obtaining true randomness of a response, the device had to be constructed in such manner as to withstand use for a considerable period of time and still maintain the possibility of providing random response. The devices of the prior art were deficient in these respects since they were unduly complicated and also, after a period of time, were not capable of providing true random responses. The present invention obviates these and other problems in the provision of a device having a movable doll's head which is capable of providing a nodding movement signifying a "yes" answer and a turning, or so-called "shaking" movement, which signifies a "no" answer. The device is operable by means of an actuating element, such as a card, which is inserted in the device for initiating the response of the doll's head. The random movement is created by a camming wheel which operates in conjunction with a latch, the latter controlling either of the movements. The camming wheel is freely rotated such that the high cam surfaces and low cam surfaces will determine the position of the latch and, hence, the movement of the doll head. OBJECTS OF THE INVENTION It is, therefore, a primary object of the present invention to provide a doll's head having two degrees of randomly selected movement, one of which signifies a "yes" answer and the other of which signifies a "no" answer by means of a unique camming means which independently and randomly controls the movement of the doll's head. It is another object of the present invention to provide a device of the type stated which is capable of being manufactured at a relatively low unit cost and which is, nevertheless, highly efficient in its operation. It is a further object of the present invention to provide a device of type stated which is capable of maintaining its ability to function randomly over prolonged periods of use. With the above and other objects in view, our invention resides in the novel features of form, construction, arrangement and combination of parts presently described and pointed out in the claims. BRIEF SUMMARY OF THE DISCLOSURE A random decision-making device capable of providing both a positive and a negative response on a random basis. The device comprises a support member which is capable of a first rotational movement about a generally vertical first axis which signifies a negative response. The support plate is also capable of a second rotational movement about a generally transverse axis which signifies a positive response. A doll's head is carried by and is movable with the support member to signify either the positive or the negative response. The device is operable with an actuating element, such as a plastic card, which is used by the players of the device. This actuating element engages an arm extending downwardly from the support member and bears against the arm at a point offset from the first axis and at a point also offset from the second axis. In this way, the card tends to bias the support member in both the first and second movements. A latch is intermittently engageable with the support member and when the latch is engaged with the support member the second nodding movement occurs. However, when the latch is not engaged with the support member, the first side-to-side movement occurs which, as indicated, signifies a negative response. A rotatable camming wheel controls the position of the latch by means of high camming surfaces and low camming surfaces on the cam wheel. When the card is inserted inwardly into the device, a roller is displaced by the card out of engagement with the camming wheel. The position in which the camming wheel was left at the end of the previous determination will thereby provide the determination of whether a negative or a positive response will be rendered. When the card is pulled outwardly, the roller is rotated and biased into operative engagement with the camming wheel, thereby rotating the camming wheel on a random basis to a new position. The position in which the camming wheel comes to rest will determine whether a high cam surface or low cam surface on the camming wheel moves the latch into or out of engagement with the support member when the card is reinserted. Thus, the random selection of the next answer is preset in the device each time the user inserts the actuating card. BRIEF DESCRIPTION OF THE DRAWINGS Having thus described the invention in general terms, reference will now be made to the accompanying drawings in which: FIG. 1 is a side elevational view of the device constructed in accordance with and embodying the present invention, with the doll's head and other components shown in dotted lines for purposes of clarification; FIG. 2 is a top plan view of the device of FIG. 1; FIG. 3 is a horizontal sectional view, taken from below along line 3--3 of FIG. 1, and showing the head support structure forming part of the device; FIG. 4 is a fragmentary vertical sectional view, taken along line 4--4 of FIG. 1; FIG. 5 is a vertical sectional view taken along line 5--5 of FIG. 2, and showing a position of several of the components of the device upon entry of an actuating card; FIG. 6 is a fragmentary vertical sectional view, somewhat similar to FIG. 5 and taken along line 6-5 of FIG. 2, and showing the position of the components in the device as the actuating card is removed from the device; and FIG. 7 is a schematic view showing a vector diagram of the forces operating upon an arm connected to the support member for creating the biasing movement of the support member in the device of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now in more detail and by reference characters to the drawings, A designates a device capable of providing two degrees of randomly selected movement, one of which signifies a positive response and the other of which signifies a negative response. The device A comprises a base frame 10 having a top plate 12 rigidly secured thereto. The base frame 10 is also constructed with an integrally formed recessed portion 14 near the rearward end thereof, in the manner as illustrated in FIGS. 1 and 2 of the drawings. Secured to the top plate 12 and extending over the recessed portion 14 is an upstanding housing 16 comprised of four rectangularly located upwardly and inwardly inclined walls 18, and which are connected at their upper margins by means of a top wall 20. A card-receiving slot 22 is formed between the top plate 12 and the upper surface of the frame 10, and is provided with a card inlet aperture 24 at the forward end of the frame 10. Moreover, it can be observed that this card-receiving slot 22 extends into the recessed portion 14 and under the housing 16. The card-receiving slot 22 is designed to receive an actuating member in the form of a plastic card C, which is used to generate a response from the device. Any other form of actuating member may also be employed in this regard, in the manner as hereinafter described in more detail. Mounted on the top wall 20 of the housing 16 is a saddle structure 26 comprised of an upstanding support post 28 which is provided for rotatable movement with respect to the top wall 20 of the housing 10. The support post 28 is rotatably mounted on a fixed rod 30 which is mounted on the top wall 20 of the housing 16. In this way, the post 28 is capable of providing a rotative movement of the saddle structure 26 about a vertical axis, designated as X in FIG. 4 of the drawings. Extending outwardly from the post 28 are a pair of diametrally opposed pivot pins 32, for fixed mounting in a pair of downwardly extending flange plates 36 on diametrally opposite sides of a relatively flat support plate 38, the latter of which also forms part of the saddle structure 26. In accordance with this construction, it can be observed that the post 28 can rotate about the pivot pin 30 to cause a rotative movement of the support plate 38 about the vertical axis X, extending through the pivot pin 30. In like manner, the support plate 38 can pivot forwardly about a horizontal axis designated as X 2 through the pivot pins 32. In this way, 2° of movement are provided. For this purpose, the flange plates 36 are provided with bevelled ends 40 in order to permit the forward pivotal movement of the support plate 38. It can be observed that the axis X 2 is perpendicular to the axis X and permits pivotal movement in a plane defined by the axis X 2 . A suitable doll's head, designated as H and shown in phantom lines in FIG. 1, may be mounted on the top surface of the support plate 38. The doll's head H is generally conventional in its construction and may be provided with a flat bottom wall for adhesive securement or for other means of conventional attachment to the support plate 38. As indicated above, the doll's head is only decorative to provide the indication of either a positive or negative response. Mounted on the underside of the support plate 38 in the rearward portion thereof is a depending lug 42 (FIGS. 1 and 3), and mounted therein is the terminal end 44 of an actuating arm 46 which extends downwardly through a slot 48 (FIGS. 2 and 4) formed in the top wall 20 of the housing 16. Moreover, the arm 46 is bent forwardly and then downwardly as illustrated in FIGS. 1 and 2 of the drawings. The lower end of the actuating arm 46 is bent forwardly, in the manner as illustrated in FIG. 1, so as to be engaged by the actuating card C as it is inserted into the slot 22. In addition, a spring 52 is mounted on the inner surface of one of the walls 18 of the housing 16 or otherwise the frame 10 and is located to engage the lower end of the actuating arm 46. By further reference to FIG. 1, it can be observed that the spring 52 engages the actuating arm 46 at a point designated as Z 1 and the actuating card C engages the actuating arm 46 at a point Z 2 which is spaced upwardly from the point Z 1 . In addition, it can also be observed that the spring 52 opposes the action of the card C as it is pushed into the device A through the slot 22. Finally, and by reference to FIGS. 1, 2 and 7, it can be observed that the card C and the spring 52 engage the actuating arm 46 at a point which is displaced downwardly from the axis of rotation of the pivot pins 32, that is the axis X 2 , and also is displaced outwardly from the axis of rotation of the post 28, that is the axis X 1 . By further reference to FIG. 7, it can be observed that the card C exerts a force F 1 and the spring exerts a force F 2 opposite to that of the force F 1 . Inasmuch as these forces are applied at a point donwardly from the horizontal axis of the pivot pins 32, i.e., the axis X 1 , a resulting horizontal force F 3 occurs at the pivot pins 32. In addition, it can be observed that if this force F 3 is offset from the axis of rotation of the post 28, and if the force F 3 is unopposed, a rotation of the post 28 and the entire saddle structure 26 will result about the vertical axis X 1 passing through the pivot pin 30. In like manner, it can also be observed that if the force F 3 were opposed by means of a latch mechanism, as described hereinafter, then the resultant of the forces of F 1 and F 2 is a torque which causes pivoting of the saddle structure 26 about the horizontal axis X 2 extending through the pivot pins 32. The bevelled ends 40 on each of the depending flanges 36 serve as "stops" which set the maximum degree of inclination of the saddle structure 26 about the horizontal axis X 2 defined by the pivot pins 32, inasmuch as these bevelled ends 40 will contact the top wall 20 of the housing 16 at the maximum degree of forward movement. Mounted on the top plate 12 is a latching mechanism 54 which comprises a pair of transversely spaced sensor arms 56. The arms 56 are pivotally mounted on an upstanding block 60, which is, in turn, affixed to the top plate 12, and the pivotal movement of these arms 56 occurs through a pivot pin 62. The rearward end portions of these arms 56 extend through an aperture 64 formed within in the forwardly presented side wall 18 of the housing 16. Moreover, the arms 56 are biased downwardly by means of a spring mechanism 66 having a spring arm 68 which bears against the upper margin of one of the arms 56, in the manner as illustrated in FIGS. 1 and 2. By further reference to FIGS. 1 and 5-6, it can also be observed that the arms 56 have terminal end portions 70 which extend downwardly below the path of movement of the card C, and into the recessed portion 14. Thus, when the card C is shifted into the slot 22, the card C will engage the lower ends 70 and bias the arms 56 upwardly against the action of the spring mechanism 66. As this occurs, the arms will be shifted upwardly to the position as illustrated in FIG. 5 of the drawings. A cam pin 72 is mounted within the pair of transversely spaced apart sensor arms 56 and extends outwardly therefrom. Located between the pair of sensor arms 56 is a sleeve 74, in the manner as illustrated in FIGS. 1, 2, 5 and 6 of the drawings. Mounted on the outer end of the cam pin 72 is a camming wheel 76, which has somewhat the appearance of a gear-wheel. However, the camming wheel 76 is provided with both high camming surfaces 78 and recesses, or so-called "low" camming surfaces 80, as more specifically illustrated in FIG. 5. In addition, it can be observed that the camming wheel 76 is so constructed that the high surfaces 78 and the low surfaces 80 are irregular in shape. In other words, the high camming surfaces may be either wide or narrow in the circumferential direction and the same holds true for the camming recesses 80. By further reference to FIGS. 1, 2 and 5 of the drawings, it can be observed that a latch 82 is pivotally mounted on a pair of forwarding extending arms 84 which extend from the housing 16, by means of a pin 86. Moreover, the latch 82 is provided with a weight forward end 88, which serves as a form of a counterweight, so as to bias the forwardly presented end thereof, that is the end proximate to the inlet aperture 24, downwardly. The camming wheel 76 cooperates with the latch 82 through an extension 90 on the latch 82, in the manner as illustrated in FIG. 2 of the drawings. Also mounted in the sensor arms 56 is a roller pin 92 which carries a roller 94, the latter of which is engageable with the sleeve 74, in the manner as illustrated in FIGS. 1 and 2 of the drawings. The roller pin 92, however, is longitudinally shiftable within a slot 96 formed within the sensor arms 56, and which is more fully apparent in FIG. 1 of the drawings. Thus, as a card C is inserted in the slot 22, it will bear against the roller 94 and tend to bias the roller pin 92 within the elongated slot, outwardly from engagement with the sleeve 74. As this occurs, the camming wheel 76 will not be rotated, but the card C will still be urged forwardly within the slot 22, in the manner as illustrated in FIG. 5 of the drawings. However, when the card C is pulled outwardly in the manner as illustrated in FIG. 6, the roller 94 will extend through a slot 96 formed in the top plate 12 when the card is disengaged from the extended ends 70, and will be rotated in the direction of the arrow during movement of the card C. Moreover, the roller 94 will be urged forwardly in the direction of the movement of the card in FIG. 6, and will also engage the sleeve 74 to thereby cause rotation of the sleeve 74 and also the camming wheel 76. Referring now to FIGS. 1 and 5 of the drawings, it can be observed that the latch 82 is provided with an upwardly struck portion 98 having a rearwardly struck tab 100 which extends into a notch 102 formed on a flange plate 104 surrounding the post 28 and being movable therewith. Again, by reference to FIG. 5, it can be observed that when the latch 82 is in the lowermost position, it will be engaged in the notch 102 and when shifted to the uppermost position, as illustrated in FIG. 1, it will not be engaged with the notch 102. The latch 82 is also provided with a detent or so-called "cam-lug" 106 which is capable of engaging the high and low surfaces on the camming wheel 76, and thus responds to the position of the camming wheel 76. In accordance with this construction, it can be observed that if the detent 106 engages a low surface 80 on the camming wheel 76, then the latch 82 will be shifted to the upward position, as illustrated in the solid lines in FIG. 1 of the drawings. In like manner, if the detent 106 engages a high surface 78 on the camming wheel 76, then the tip 100 of the latch 82 will be shifted to the lowermost position, as illustrated in FIG. 5 of the drawings, where the terminal end thereof is located within the notch 102. It can also be observed that the latch 82 is also limited in its upward movement, that is, out of the notch 102, by means of a stop 108 located on the top plate 12, reference being made to FIGS. 1 and 5 of the drawings. The various components forming part of the device A with perhaps the exception of the spring mechanism (hereinafter described) in the device A can all be constructed of a number of well-known plastic materials including for example, polyethylene, polystyrene, polybutadiene, a number of known vinyladiene copolymers and the like. These components may be formed in any of a number of known plastic forming techniques including blow molding, injection molding, thermo-forming and the like. However, it can also be observed that many of the components forming part of the device A could be formed of other materials including light weight metals, such as aluminum or the like. Moreover, these various components can be formed of reinforced plastic materials as for example, resin matrix reinforced plastics including, e.g., thermosetting and thermoplastic resins along with various fiberous materials such as glass, boron, carbon or the like. The particular materials used in the construction of these components will be predicated upon necessary strength requirements and desired durability as well as manufacturing costs. In accordance with the above-outlined construction, it can be observed that as the user of the device inserts a card C into the slot 22, it will bias the roller 94 out of engagement with the sleeve 74. Moreover, the card C will continue to be inserted into the slot 22 until it engages the lower end 70 of the sensor arms 56, thereby biasing the sensor arms 56 upwardly. Moreover, the card C will also engage the actuating arm 46. As this occurs, the actuating arm 46 will be biased rearwardly against the action of the compression spring 52. By means of this action, there will be a tendency to rotate the saddle 26 about the vertical axis X 1 and also about the horizontal axis X 2 . The actual movement which will occur will be dependent upon the position of the latch 82. If the latch 82 is in the upper position, as illustrated in FIG. 1 of the drawings, then the support plate 38, and hence the entire saddle mechanism 26, will be permitted to rotate about the vertical axis X 1 through the post 28. However, if the latch 82 is in the lower position, as illustrated in FIG. 5 of the drawings, then only the pivotal movement of the support plate 38, and hence the head H, will be permitted in the vertical plane about the axis X 2 . It can be observed by reference to the force diagram of FIG. 7 that there will be a greater tendency for the support plate to rotate than pivot. Thus, if the latch is in the upper position, rotational movement will occur without the need for preventing the pivotal movement. When the card C is withdrawn from the apparatus, it can be observed that the card will engage the roller 94, thereby biasing the roller pin 92 rearwardly within the slot 96. In this case, the roller 94 will engage the sleeve 74 and thereby cause rotation of the camming wheel 76. This rotation of the camming wheel 76 will continue until the card C is fully disengaged from the roller 94. Nevertheless, during the removal of the card C, the roller 94 will continue to rotate and thereby rotate the camming wheel 76. As the card C is removed from engagement with the roller 94, rotation of the roller 94 will cease and, hence, rotation of the camming wheel 76 will also cease. However, it can also be observed that as the high and low portions on the camming wheel 76 are irregular, the exact position of the camming wheel is only determined by the removal of the card C. Accordingly, if a high camming surface 78 on the camming wheel 76 is in contact with the detent 106, then the latch 82 will be biased toward the upper position. In like manner, if the detent 106 is in engagement with a low camming surface 80, then the latch 82 will be biased to its upper position. Accordingly it can also be observed that if the latch 82 is biased to its upward position, then, upon the entry of a card C on the next determination, a rotative or negative response will be obtained. In like manner, if the detent 106 is located in a high camming area 80, then the latch 82 will be engaged in the slot 102 and it will permit only pivotal movement of the saddle mechanism 26. In this way, only a positive response will be achieved on the next determination. In accordance with this construction, it can be observed that the determination of a response is predicated upon the position of the camming wheel 76 which is, in turn, dependent upon the removal of the card C in the previous determination. Thus, there has been illustrated and described a unique and novel device which permits two degrees of movement on a randomly selected basis operable with a unique camming means, and which therefore fulfills all of the objects and advantages sought therefor. It should be understood that many changes, modifications, variations and other uses and applications will become apparent to those skilled in the art after considering this specification and the accompanying drawings. Therefore, any and all such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention, which is limited only by the following claims.
A movable doll's head having two randomly selected movements, one a nodding movement signifying a "yes" answer, and the other a turning or "shaking" movement signifying a "no" answer. The doll's head is mounted on a support plate which is pivotally mounted for movement about a pair of axes. An actuating element, such as a playing card, may be introduced into the device so as to engage a portion of the support plate at a point offset from both axes of movement, thereby tending to cause movement about both the axes. However, a latch is operatively engageable with the support plate, to thereby cause movement to occur about only one of the axes. A camming wheel is randomly rotated by the movement of the card into and out of the device, with the resultant position of the camming wheel determining the latched or unlatched position of the latch. This in turn produces movement of the head on a random basis.
0
CROSS REFERENCE TO RELATED APPLICATIONS The present application is a continuation of U.S. patent application Ser. No. 12/266,656, filed Nov. 7, 2008, now U.S. Pat. No. 8,027,029, which claims the benefit of U.S. provisional application Ser. No. 60/986,016, filed Nov. 7, 2007, which is hereby incorporated herein by reference in its entirety. BACKGROUND OF THE INVENTION It is known to detect objects or other vehicles with camera vision systems. Examples of such vision systems are described in U.S. Pat. Nos. 5,796,094; 6,097,023; 6,320,176; 6,313,454; 6,559,435; 6,831,261; 6,396,397; 5,877,897; 6,498,620; 5,670,935; 6,806,452; 6,946,978; 7,123,168; 7,004,606; 7,005,974; and/or 5,550,677, which are hereby incorporated herein by reference in their entireties. SUMMARY OF THE INVENTION The present invention provides a road object detection and tracking systems that is based on the fusion of camera vision and Lidar technologies. The system and concept can provide driver assistance and safety functions, such as adaptive cruise control, stop and go control, pedestrian detection, front and rear collision warning, lane departure warning, side object detection, rear object detection, side and/or rear and/or front blind zone detection, and/or the like. For the above mentioned driver assistance and safety applications, it is important to detect and identify objects on the road, and is desirable to measure object distance and relative speed to the driver's own vehicle (the host or subject vehicle). The proposed technology has the advantages over others to fulfill these requirements. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram of the Lidar and camera-based vision system of the present invention; FIGS. 2A-C are side elevations of a vehicle having a Lidar and camera-based vision system incorporated therein in accordance with the present invention; FIGS. 3A-D are schematics of different means for steering the Lidar light source and detector line of sight in accordance with the present invention; and FIGS. 4A and 4B are images of the field of view of the imaging sensor or camera of the Lidar and camera based system of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings and the illustrative embodiments depicted therein, a combined vision and Lidar system 10 of the present invention provides a combination of the core of Lidar and camera based vision modules (see FIG. 1 ). The camera vision module 12 is comprised of a lens 12 a , an imager 12 b , a vision ECU 12 c and vision algorithm. The vision module detects and identifies objects in the field of view. The Lidar module or system 14 in general is comprised of a light source 14 a , a light detector 14 b , lenses for source and detector, a scanning device 14 c , a modulation signal generator, a signal amplifier, and a signal processing unit 14 d . Lidar system 14 measures object distance by comparing the modulation phase or calculating a time of flight of the light from the object (such as by utilizing processes such as those described in U.S. Pat. Nos. 6,825,455; 7,053,357; 7,408,627; 7,405,812; 7,379,163; 7,379,100; 7,375,803; 7,352,454; 7,340,077; 7,321,111; 7,310,431; 7,283,213; 7,212,663; 7,203,356; 7,176,438; 7,157,685; 6,919,549; 6,906,793; 6,876,775; 6,710,770; 6,690,354; 6,678,039; 6,674,895; and/or 6,587,186, which are hereby incorporated herein by reference in their entireties). Lateral and vertical resolution of a scene can be realized by mechanically scanning the light beam in a raster fashion, such as in a manner similar to known or conventional Lidar systems, such as those described in the patents incorporated by reference above. In the illustrated embodiment, and as shown in FIG. 1 , the vision system camera 12 b is used to provide lateral and vertical resolution of the scene. The mechanical scanner does not need to perform raster scanning; instead, the Lidar line of sight and/or source light is guided by the vision module to point to the objects of interest and measure the distances between the objects and the host or subject vehicle, as discussed below. The Lidar light source can be any suitable light source, such as, for example, a laser operating in an infrared wavelength (or near infrared) and eye-safe, a LED or LED array operating in the infrared or near infrared region and eye-safe, and/or one or more vehicle headlamps. Optionally, for example, the laser or LEDs 14 a can be mounted as a part of the camera-Lidar module that is mounted behind the rear view mirror 16 inside the vehicle compartment, such as shown in FIG. 2A . Optionally, the laser or LEDs 14 a ′ can be mounted separately from camera-Lidar module, such as shown in FIG. 2B . Optionally, and as shown in FIG. 2C , the system may utilize the vehicle headlamp 18 as the Lidar light source 14 a ″. In this case, high frequency pulse width modulation may be applied to the headlamp. Optionally, LEDs as the Lidar source can be built inside the headlamp assembly. Clearly, the Lidar source may comprise other light sources and/or may be disposed elsewhere at the vehicle while remaining within the spirit and scope of the present invention. When using laser as the Lidar light source, the laser may be collinear to the detector line of sight and steered by the same steering mechanism. It can also be steered by a separate steering mechanism, which is synchronized with the detector line of sight steering. The boundary of the scanned light should match vision camera's field of view boundary. When using LEDs as the Lidar light source, the LED light should be collimated and then steered, or the LED(s) may be designed to spread the light to cover the whole field of view. To provide a steering mechanism to the Lidar light source and detector line of sight, one can use any suitable steering means, such as, for example, via one of the following methods: (i) move the lens 14 e in X and Y translational directions by mechanical means ( FIG. 3A ); (ii) move the detector 14 b in X and Y translational directions by mechanical means ( FIG. 3B ); (iii) reflect light by two scanning mirrors 15 a , 15 b that rotate in orthogonal directions that equivalently provide X and Y movements ( FIG. 3C ); and/or (iv) reflect light by one or two micro mirror array (MEMS) devices 15 a ′, 15 b ′ that steer light in X and Y directions ( FIG. 3D ). Optionally, the steering mechanisms described in FIGS. 3A and 3B can be realized by a “speaker coil” type actuator that moves the lens or detector, or a piezoelectric actuator that drives the lens or detector in translation motions, or a servo/step motor to drive the lens or detector in translation motions, or any other suitable means. Optionally, the steering mechanisms described in FIG. 3C can be realized by a “galvanometer” type scanning mirror, or a piezoelectric actuator to drive the lens or detector in rotation motions, or a servo/step motor to drive the lens or detector in rotation motions or other suitable means. The basic sequence of the operation may include the following. The vision camera may acquire an image frame or frames at a certain rate (such as, for example, about 30 frames per second (fps) or thereabouts). The vision processing algorithm processes image(s) and identifies object(s) of interest in the field of view of the imager or camera. A signal or data indicative of the X and Y coordinates of the objects is communicated to a Lidar steering unit. The Lidar unit is steered to direct the light toward a first object based on the given coordinates and the unit may measure the distance to the first object, and the Lidar unit may be steered to direct the light toward a second object or objects and may measure distance to the next object or objects, and so on, until all objects and distances are measured. The system may calculate speed data for all objects if necessary or desired, and may feed the distance and speed data back to an object identification algorithm to improve object identification and prioritization. These steps may be repeated during operation of the system. The system provides 3 dimensional and 1 timing information of a road object(s) relative to the vehicle that hosts the system. The information provided may include the X and Y coordinates of an object in the camera's field of view, the distance (Z) between the object(s) and the host vehicle, and the time of possible collision based on the speed of the object and the host vehicle. The vision module acquires, processes and identifies objects that are of interest to the applications, such as vehicles, pedestrians, roadside buildings, traffic lights, traffic signs, tail lights and head lights, and/or the like. The vision system may also identify lane markers, curbs and/or road dividers to help to determine the lane that the host vehicle is in and where the other vehicles or objects are relative to that lane. Identifying if another vehicle is in the host vehicle's lane is useful for adaptive cruise control systems (ACC) and/or stop and go applications and/or collision warning applications. Algorithms that have already been developed in Lane Departure Warning systems can serve that purpose. Lidar measures the distance from an object to the host vehicle. By adding this distance information to the 2-dimensional object position information, the algorithm can construct full 3-dimensional position information of an object or objects. The timing information given by the video frames, along with the host vehicle speed information (read from vehicle bus), enable the calculation of the object speeds. The distance and speed information can also feedback to the vision algorithm to help its object identification. Besides the X and Y coordinates of the objects that the camera vision module gives, the distance and speed information add two more dimensions to identify objects. In addition, lane mark information adds critical information for applications like ACC and collision warning. Based on the objects' 4-dimensional information and lane mark information, a map of road objects can be generated. Priority scores can be assigned to all objects in the image. The priority scores represent the danger or importance of the objects detected in a scene. The objects with high priority scores have one, a few or all of the following characteristics: vehicles that are close to the host vehicle; vehicles that are closing to the host vehicle in relative speed and collision will happen in pre-determined time; vehicles that are in the same lane of the host vehicle; vehicles that are moving to the same lane of the host vehicle (a vehicle cut in the lane at a close distance in front of the host vehicle); and/or a pedestrian moving toward the center of the view. In traditional Lidar systems that provide and process a full field of view, the beam is scanned in raster fashion, or multiple detectors are scanned in sequence, in which case an equal amount of time is allocated to all of the objects in the field of view. However, the system in accordance with the present invention can assign different amounts of “staring” time to the different objects. A longer time may be assigned to the objects with higher priority scores. The coordinates of an object identified by the imager sensor guides the steering mechanism of the Lidar. The Lidar sight can track and stay on an object while the object moves in the camera's field of view. As can be seen with reference to FIGS. 4A and 4B , the coordinates (X,Y) may be given by the image sensor to an identified vehicle 20 in the field of view. The Lidar sight, which is represented by the circle in FIGS. 4A and 4B , is guided to point to the vehicle. By staring for a longer time at one object or a limited number of objects in the field of view and avoiding time consuming mechanical steering across the scene, the Lidar can provide faster distance reading of one object or a limited number of objects in the field of view. The system provides the vehicle control module or modules with faster distance inputs, and thus allows quicker reaction time or speed and enhanced control to enhance avoidance of a collision with objects such as a pedestrian or another vehicle. For example, in an ACC application, the vehicle in front of the host vehicle and in the same lane has the highest priority score and will be stared by the Lidar for the most amount time and the system will update the distance data to the vehicle controllers more frequently, in order to maintain the safe distance and avoid a collision with the other vehicle. In pedestrian detection application, a pedestrian's distance and relative speed should be monitored to determine if his/her trajectory potentially runs into the host vehicle. The pedestrians who have more probability of running into the host vehicle are assigned higher priority scores and then they get a greater amount of the Lidar time and more frequent distance updates. In collision warning applications, the highest priority score may be assigned to a vehicle in the driver's or host vehicle's lane that is approaching to a position and speed that will collide with the driver's own vehicle within a pre-defined time. The system stares at the vehicle for most of the time and updates the distance information to the vehicle controller more frequently to allow the vehicle controllers to take quicker reaction. In stop-and-go applications, the system may track the nearest vehicle in front of the subject or host or equipped vehicle and in the same lane, and may identify, track and react to cut-in vehicle from next lanes. Those nearest vehicles or cut-in vehicles are assigned with most of the staring time and updates of distance measurement at the highest frequency in order to provide the vehicle controller a quicker reaction time or speed. While the Lidar sight tracks high priority score objects for more time, it is also important to monitor low score objects at a reasonable frequency. Some objects may grow to higher priority ones and some objects may change to reduced priority scores. Continuous and real time monitoring and score assessment is desirable during operation of the system of the present invention. Unlike the raster scanning mechanism in known Lidar systems (which have to scan a full raster field of view for each frame), the Lidar system of the present invention has advantages of faster steering and object tracking capability that are unique compared to competing technologies. By nature, the objects being tracked move slow in the horizontal and vertical directions in the camera and Lidar field of view. So the mechanical scanning takes much less time to track objects or hop or switch between the objects. In addition, the system does not have to waste scanning time in most of the “empty” space or spaces in the field of view that have no objects of interest. In other words, the system of the present invention can provide faster scene sampling rate or tracking speed than the regular raster scan Lidar system and multiple detector system. On the other hand, for the same or similar tracking speed, the present invention may require a relatively slower mechanical scanning speed, which may lead to a lower cost and higher durability of the scanning mechanics. Another advantage of the present invention is that the system of the present invention may provide a more efficient and accurate distance measurement, because it can stay at or process an object of interest for a longer time than the raster scanning Lidar does on the objects. Traditional raster scanning Lidar evenly spreads the beam in the full field of view and therefore has a shorter exposure time for each and every object in the field of view. Without wasting time on raster scanning, the system of the present invention can provide higher distance sampling rate than regular Lidar and Radar. The system of the present invention may provide more accurate distance measurement because the Lidar beam can stay on an object for longer time. The system allows more pulses to be collected and special algorithms or techniques to be applied to enhance the detection sensitivity and confidence level. For example, the system may use a gated accumulation and average (Boxcar technique) of many pulses of light to increase the signal to noise ratio. Also, the system of the present invention may provide more accurate distance measurement because the object detection in the two dimensional image helps steer the Lidar beam in a more accurate angle. In addition, the distance reading of an object increases the confidence level of the two dimensional vision object detection, which in turn provides feedback to the Lidar and provides a more accurate distance measurement. Another benefit of being able to “stare” longer on the object is that it provides enhanced performance in adverse weather conditions, such as rain or fog. One known disadvantage of known Lidar systems is the difficulty the system has in seeing long distances through rain or fog. The light is scattered or diffused by the water droplets in the rain and fog and causes the return light signal to be too weak to detect. However, by staying longer on objects, the system of the present invention can gather more light pulses and apply special methods and algorithms to enhance the detection sensitivity and confidence level. For example, one can use gated accumulation and average (Boxcar technique) of many pulses of light to increase signal to noise ratio. The beam or line of sight steering needs to provide the field of view that is needed for matching the camera field of view and application needs. A focused Lidar source light and detection spot can deliver better resolution and higher sensitivity over known systems. Camera vision provides high lateral and vertical resolution and the mature imaging processing technology allows sufficient or enhanced object identification, lane mark detection, and/or the like in high speed by utilizing mature color CMOS or CCD imagers. Lidar, on the other hand, provides excellent longitudinal resolution. Both are mature technologies with relative lower costs as compared with other competing technologies, such as Radar or the like. By combining these two technologies together, the present invention provides advantages in performance (such as high resolution in lateral, vertical and longitudinal dimensions; high detection and tracking speed; and reliable object identification and tracking), costs (such as due to the ability to combine circuits to share components; combine processor and memory; and lower speed mechanical scanning mechanics), size (smaller package size; main Lidar components can be integrated with the camera; and the system may be placed behind rear view mirror) and integration with existing vision-based systems, such as LDW, IHC, AFS, TSR and/or night vision systems and/or the like. Applications of such a vision-Lidar fusion system include (i) adaptive cruise control (ACC), (ii) Stop and Go; (iii) pedestrian detection; (iv) collision warning at both front and rear sides of the vehicle; (v) predictive brake assist; (vi) side object detection, (vii) side blind zone object detection; (viii) rear blind zone object detection; (ix) parking assist; and/or (x) lane change aid detection (a side object detection system may include both blind zone and lane change aid functions) and/or the like. Therefore, the present invention provides enhanced processing techniques over prior art technology, including scanning Lidar (which scans the whole field of view and has a slower tracking speed and is not as good at identifying objects in a complex scene and is not as good at detection in fog or rain); Radar (which is expensive and has a low horizontal resolution (only a few lobes) and is not as good at identifying objects in a complex scene); stereo vision (which requires two cameras and needs a wide baseline and rigid body, requires complex stereo image processing and has its distance accuracy limited by the camera separation); 2-D vision (which requires complex image processing and is not as accurate in measuring distances and does not provide reliable distance information for variable sizes of detected vehicles); range imager (an imager technology that can measure object distance by time of flight of the light pulses emitted by the light emitter, in addition to regular 2D image, and with the distance sensing being at the imager chip level, which is a complex semiconductor sensor fabrication and is a higher cost system). Optionally, the imaging sensor of the present invention may comprise a two-dimensional pixelated imaging array having a plurality of photo-sensing pixels arranged or disposed or established on a semiconductor substrate. For example, the imaging sensor may comprise a complementary-metal-oxide-semiconductor (CMOS) or a CCD imaging sensor or device or the like, and may utilize aspects of the imaging sensors described in U.S. Pat. Nos. 5,796,094; 6,097,023; 6,320,176; 6,313,454; 6,559,435; 6,831,261; 6,396,397; 5,877,897; 6,498,620; 5,670,935; 5,760,962; 6,806,452; 6,946,978; 7,339,149; 7,123,168; 7,004,606; 7,005,974; and/or 5,550,677, and/or PCT Application No. PCT/US07/75702, filed Aug. 10, 2007, and/or U.S. patent application Ser. No. 11/239,980, filed Sep. 30, 2005; Ser. No. 11/105,757, filed Apr. 14, 2005 by Schofield et al. for IMAGING SYSTEM FOR VEHICLE; and/or Ser. No. 10/534,632, filed May 11, 2005; and/or PCT Application No. PCT/US2003/036177, filed Nov. 14, 2003 by Donnelly Corp. for IMAGING SYSTEM FOR VEHICLE, and published Jun. 3, 2004 as PCT Publication No, WO 2004/047421; and/or PCT Application No. PCT/US2006/041709, filed Oct. 27, 2006 and published May 10, 2007 as International Publication No. WO 07/053,404, which are hereby incorporated herein by reference in their entireties. Optionally, the system may include any imaging sensor or sensors, and may utilize aspects of various vision or imaging or detection systems, such as, for example, blind spot detection systems described in U.S. Pat. Nos. 7,038,577; 6,882,287; 6,198,409; 5,929,786; and/or 5,786,772, and/or U.S. patent application Ser. No. 11/239,980, filed Sep. 30, 2005; and/or Ser. No. 11/315,675, filed Dec. 22, 2005, and/or U.S. provisional application Ser. No. 60/638,687, filed Dec. 23, 2004; Ser. No, 60/628,709, filed Nov. 17, 2004; Ser. No. 60/614,644, filed Sep. 30, 2004; and/or Ser. No. 60/618,686, filed Oct. 14, 2004, and/or road surface detection systems, such as of the types described in U.S. patent application Ser. No. 11/948,086, filed Nov. 30, 2007, and U.S. provisional application Ser. No. 60/872,270, filed Dec. 1, 2006, and/or reverse or backup aid systems, such as rearwardly directed vehicle vision systems of the types described in U.S. Pat. Nos. 7,005,974; 5,550,677; 5,760,962; 5,670,935; 6,201,642; 6,396,397; 6,498,620; 6,717,610 and/or 6,757,109, and/or of automatic headlamp control systems of the types described in U.S. Pat. Nos. 5,796,094 and/or 5,715,093; and/or U.S. patent application Ser. No. 11/105,757, filed Apr. 14, 2005; and/or U.S. provisional application Ser. No. 60/607,963, filed Sep. 8, 2004, and/or rain sensors or rain sensing systems of the types described in U.S. Pat. Nos. 6,250,148 and 6,341,523, and/or of other imaging or detecting systems, such as the types described in U.S. Pat. Nos. 6,353,392 and 6,313,454, and/or U.S. patent application Ser. No. 11/948,086, filed Nov. 30, 2007; Ser. No. 12/171,436, filed Jul. 11, 2008; and/or Ser. No. 12/190,698, filed Aug. 13, 2008; and/or U.S. provisional application Ser. No. 60/872,270, filed Dec. 1, 2006; Ser. No. 60/949,352, filed Jul. 12, 2007; Ser. No, 60/956,633, filed Aug. 17, 2007; and/or PCT Application No. PCT/US07/75702, filed Aug. 10, 2007; and/or PCT Application No. PCT/US08/78700, filed Oct. 3, 2008; and/or PCT Application No. PCT/US08/76022, filed Sep. 11, 2008, with all of the above referenced U.S. patents, patent applications and provisional applications and PCT applications being commonly assigned and being hereby incorporated herein by reference in their entireties. Optionally, the imaging sensor may be suitable for use in connection with other vehicle imaging systems, such as, for example, a blind spot detection system, where a blind spot indicator may be operable to provide an indication to the driver of the host vehicle that an object or other vehicle has been detected in the lane or area adjacent to the side of the host vehicle. In such a blind spot detector/indicator system, the blind spot detection system may include an imaging sensor or sensors, or ultrasonic sensor or sensors, or sonar sensor or sensors or the like. For example, the blind spot detection system may utilize aspects of the blind spot detection and/or imaging and/or indicating systems described in U.S. Pat. Nos. 7,038,577; 6,882,287; 6,198,409; 5,929,786; and/or 5,786,772, and/or U.S. patent application Ser. No. 11/315,675, filed Dec. 22, 2005; Ser. No. 11/239,980, filed Sep. 30, 2005; and/or Ser. No. 11/933,697, filed Nov. 1, 2007, and/or PCT Application No. PCT/US2006/026148, filed Jul. 5, 2006 and published Jan. 11, 2007 as International Publication No, WO 2007/005942, and/or PCT Application No. PCT/US07/082,099, filed Oct. 22, 2007 and published May 2, 2008 as International Publication No. WO 2008/051910, and/or U.S. provisional application Ser. No. 60/618,686, filed Oct. 14, 2004; Ser. No. 60/853,850, filed Oct. 24, 2006; Ser. No. 60/918,089, filed Mar. 15, 2007; Ser. No. 60/970,687, filed Sep. 7, 2007; and/or Ser. No. 60/857,025, filed Nov. 6, 2006, and/or of the reverse or backup aid systems, such as the rearwardly directed vehicle vision systems described in U.S. Pat. Nos. 5,550,677; 5,760,962; 5,670,935; 6,201,642; 6,396,397; 6,498,620; 6,717,610; 6,757,109; and/or 7,005,974, and/or of the rain sensors described in U.S. Pat. Nos. 6,250,148 and 6,341,523, and/or of other imaging systems, such as the types described in U.S. Pat. Nos. 7,123,168; 6,353,392 and 6,313,454, with all of the above referenced U.S. patents, patent applications and provisional applications and PCT applications being commonly assigned and being hereby incorporated herein by reference in their entireties. Typically, customer specifications may require blind spot sensors, such as blind spot radar sensors and the like, to detect when they are blind due to the buildup of dirt, ice or snow in front of the sensor. This is also true for side object detections sensors which include side blind spot and lane change aid sensors. In practice, for many of these sensors, meeting those requirements can present a challenge, since the buildup cannot be actively detected, but rather has to be inferred from the lack of radar returns over a longer time. That works adequately in driving environments that have a lot of natural returns or objects for the system to detect as the vehicle travels along the road (such as guardrails and/or other vehicles and/or the like), but on some roads (such as some elevated roads where a sensor may not detect any object to the side of the host vehicle for minutes), such a system may fail. If the host vehicle is driven along such roads (such as some elevated roads in Sweden where a blind spot detecting sensor may not see anything for minutes), the absence of such a detection may trigger the blockage detection sensor. It is thus envisioned that such a blind spot detection system be combined with an input from a forward facing camera of the vehicle (such as a camera that is part of a headlamp control system or lane departure warning system or object detection system or the like of the vehicle). Thus, a blockage detection at the BSD sensor may be determined by the lack of detection of an object after that object is detected by the forward facing camera. For example, if the front sensor or camera detects that the host vehicle is passing another vehicle or structure, but the blind spot detecting sensor does not detect the object a short period of time later (depending on the speed of the vehicle), the system can determine that the blind spot detecting sensor has a blockage, whereby the system can detect such blockages much quicker than previously possible. Changes and modifications to the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law.
An object detection system for a host vehicle includes an imaging device, a ranging device and a processor. The imaging device has a field of view exterior of the host vehicle and is operable to capture image data representative of an object exterior the host vehicle. The ranging device has a field of view that sweeps at least the field of view of the imaging device and that detects the object exterior the host vehicle. The processor processes image data from the imaging device and processes data from the ranging device in order to determine if the detected object is an object of interest. The determination that the detected object is an object of interest is made in accordance with a priority score.
6
BACKGROUND OF THE INVENTION 1. Field of the Invention The field of invention relates to adjustable chair structure, and more particularly pertains to a new and improved swing arm chair apparatus wherein the same is arranged to permit pivotal displacement of an arm member relative to the chair structure for ease of access in entry and exit relative to the chair structure. 2. Description of the Prior Art Chairs of various types have been utilized throughout the prior art to accommodate adjusting for height, back support, and the like. U.S. Pat. No. 3,829,159 to Leffler sets forth a chair structure having pivotally mounted side arms to permit ease of access to the chair in use as a treatment chair structure. U.S. Pat. No. 3,563,604 sets forth chair structure having arm rest members pivotally mounted to permit displacement of the arm rest relative to the chair structure. As such, it may be appreciated there continues to be a need for a new and improved swing arm chair apparatus as set forth by the instant invention which addresses both the problems of ease of use as well as effectiveness in construction permitting ease of entry and exit relative to the chair structure and in this respect, the present invention substantially fulfills this need. SUMMARY OF THE INVENTION In view of the foregoing disadvantages inherent in the known types of chair apparatus now present in the prior art, the present invention provides a swing arm chair apparatus wherein the same utilizes a swing arm mounted to the chair structure to permit displacement of the swing arm for ease of entry and withdrawal relative to the chair structure. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved swing arm chair appartus which has all the advantages of the prior art chair apparatus and none of the disadvantages. To attain this, the present invention provides a chair member including first and second arms, with the first arm pivotally mounted to the chair to permit ease of access to individuals of diminshed physical capacity permitting ease of access and exit relative to the chair. The swing arm includes a latch mechanism to permit ease of latching of the swing arm relative to the chair structure. My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified. There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way. It is therefore an object of the present invention to provide a new and improved swing arm chair apparatus which has all the advantages of the prior art chair apparatus and none of the disadvantages. It is another object of the present invention to provide a new and improved swing arm chair apparatus which may be easily and efficiently manufactured and marketed. It is a further object of the present invention to provide a new and improved swing arm chair apparatus which is of a durable and reliable construction. An even further object of the present invention is to provide a new and improved swing arm chair apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such swing arm chair apparatus economically available to the buying public. Still yet another object of the present invention is to provide a new and improved swing arm chair apparatus which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith. These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention. BRIEF DESCRIPTION OF THE DRAWINGS The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein: FIG. 1 is an isometric illustration of a prior art swing arm type chair construction, as indicated in U.S. Pat. No. 3,829,159. FIGS. 2 and 3 are isometric illustrations of a chair structure having a pivotally mounted medial arm rest, as indicated in U.S. Pat. No. 3,563,604. FIG. 4 is an isometric illustration of the invention with the swing arm in a first position. FIG. 5 is an isometric illustration of the chair structure in a second position. FIG. 6 is an isometric illustration of the latching and pivoting structure of the swing arm member. FIG. 7 is an isometric illustration of the side wall top plate having recesses for mounting a desk plate and storage compartment. DESCRIPTION OF THE PREFERRED EMBODIMENT With reference now to the drawings, and in particular to FIGS. 1 to 7 thereof, a new and improved swing arm chair apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described. More specifically, the swing arm chair apparatus 10 of the instant invention essentially comprises a chair structure having a chair seat 11, with a chair back support 12 extending upwardly relative to the chair seat, and the chair including a base portion having a first side wall 13 spaced from a second side wall 14, and a front wall 15. A first arm extends from the back support 12 to the front wall 15 along the first side wall 13. Similarly, a second arm 17 extends along the second side wall 14 from the back support 12 to the front wall 15. The first side wall (see FIGS. 5 and 6 for example) includes a first side wall top wall 18 oriented at an oblique angle relative to the first side wall, and extends from the first side wall to the chair seat coextensive with the first side wall. A top wall lock bore 19 is orthogonally directed into the top wall 19 in adjacency to the front wall 15 and the chair seat 11. The arm is formed with a first arm bottom wall 20, with a first arm bottom wall axle 21 orthogonally oriented to the first bottom wall 20 and directed into the first side wall top wall 18. The first arm bottom wall axle 21 is received through an axle bore 22 directed through the top wall 18 in a spaced relationship relative to the lock bore 19 parallel to the lock bore, with the first arm bottom wall axle 21 oriented in a parallel relationship relative to the lock bore 19 and positioned in adjacency relative to a rear distal end of the first arm bottom wall 20. Oriented adjacent a forward end of the first arm bottom wall 20 is a cylindrical latch bolt 23 having a latch bolt axis 23a. A latch bolt arm 24 orthogonally oriented relative to the axis 23a is integrally and medially mounted relative to the latch bolt 23. A latch bolt rod 25 has an upper distal end indicated as a bifurcated first end 26 pivotally mounted to the latch bolt arm 24 to permit pivotal relationship of the latch bolt arm 24 relative to the latch bolt rod 25, whereupon pivoting of the latch bolt 23 provides for selective lifting of the latch bolt rod 25 relative to the top wall lock bore 19 to permit displacement of the swing arm or first arm 16 to the second position, as indicated in FIG. 5. To ease such rotation of the latch bolt 23, a latch bolt lever 27 orthogonally mounted and integrally secured to the latch bolt 23 at a free end thereof exteriorly of the first arm 16 between the first arm 16 and the second arm 17 is mounted to permit ease of lifting of the latch bolt rod 25, in a manner as indicated in FIG. 6 for example. A plurality of latch bolt saddles 28 extend about the latch bolt 23 and are secured to a top surface of the top wall 18, with the latch bolt arm 24 as indicated oriented between the latch bolt saddles 28. FIG. 7 indicates the use of a somewhat modified top wall 18 having a top wall recess 29 extending medially of the top wall, having a recess floor 30 positioned below a top surface of the wall a predetermined height. A floor recess cavity 31 is directed into the recess floor 30 for storage of various components such as pencils, pens, and the like. A desk plate 32 having a predetermined thickness equal to the predetermined height is pivotally mounted about a desk plate axle 33, with the desk plate axle 33 orthogonally directed into the recess floor 30 in a parallel relationship relative to the top wall lock bore 19. In this manner, access to the desk plate 32 is provided for use as a desk structure, wherein various pencils and the like may be stored within the recess floor cavity 31 for use with the desk plate 32. As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
A chair member includes first and second arms, with the first arm pivotally mounted to the chair to permit ease of access to individuals of diminished physical capacity permitting ease of access and exit relative to the chair. The swing arm includes a latch mechanism to permit ease of latching of the swing arm relative to the chair structure.
0
This application is a continuation application of reissue application Ser. No. 11/219,229, filed Sep. 2, 2005 now U.S. Pat. No. RE. 40,306 that claims priority to Ser. No. 09/478,861, filed Jan. 7, 2000 and issued at U.S. Pat. No. 6,615,290. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an end-of-scan reporting system. More particularly, the present invention relates to a system that reports the completion of a scanning session to a user through computer peripheral components. 2. Description of the Related Art Due to progress in multi-media technologies, advanced image processing techniques have lead to the development of many peripheral image processors. A scanner is one of the imaging processors that have recently become an indispensable piece of equipment. Developed from earlier versions of the black-and-white palm top scanner, full color high-resolution scanners capable of producing fine real images are widespread nowadays. Currently, most scanners in the market have a user interface capable of reporting to the user as soon as a scanning session is complete so that the user can plan the next task. In general, when a picture or document is being scanned, a user must watch for the end of the scanning session. As soon as a scanning session is complete, a scan completion icon appears on a computer screen through the user interface. Next, the user has to replace the page with a new one and then watch the computer screen again to find out when the scanning session ends. This type of operation is likely to prevent the user from performing other tasks. Alternatively, if the user spends time doing other asks, the user may miss the end of session notice displayed on the computer screen and leave the scanner in an idle state. Hence, the current method of operating the scanner is quite inconvenient. Some higher-grade scanners now include an automatic document feeder (ADF) so that the user can put a number of pages into a tray and extend each scanning session. At the end of the multi-paper scanning session, an end-of-scanning icon is similarly displayed on the computer screen through the user interface so that the user is notified. However, if the user is occupied with some other tasks at that time, the end-of-scan notice may be missed. Hence, the scanner will still be left in an idle state for quite some time. SUMMARY OF THE INVENTION The invention provides a method of reporting the end of a scanning session to a user. The method includes determining the types of peripheral devices needed to report to the user at the end of a scanning session. When the current scanning task is complete, the selected peripheral devices automatically informs the user of the end of the scanning session. This invention also provides a method of reporting the end of a scanning session to a user. The method includes using a computer to detect all the available peripheral devices for reporting the end of a scanning session. The most suitable peripheral device or devices for reporting end of scanning session to the user are then chosen. After the current scanning session is complete, the end of session notice is signaled to the user via the selected peripheral devices. Next, the computer decides if there is any further scanning task to perform. If there is any other scanning task to perform, the most suitable peripheral device or devices for reporting the end of a scanning session to the user is again chosen. If no more tasks are pending, the reporting system halts. Accordingly, the present invention is to provide a reporting system capable of notifying a user of the end of a scanning session through computer peripheral devices. In addition, the invention is to provide a method of reporting the end of a scanning session to a user in real time so that subsequent scanning operations can proceed immediately with no delays. Hence, idle time of the scanner is greatly reduced. It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed. BRIEF DESCRIPTION OF THE DRAWING The accompanying drawing is included to provide a further understanding of the invention, and is incorporated in and constitutes a part of this specification. The drawing illustrates embodiments of the invention and, together with the description, serves to explain the principles of the invention. In the drawing, FIG. 1 is a flow chart showing the steps carried out in an end-of-scanning reporting system according to this invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawing. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts. The end-of-scan reporting system in this invention is achieved by appending application programs to the user interface program of a scanner. When the user interface picks up an end-of-scan signal from the scanner, an end-of-scan icon will be displayed on the computer screen as before. However, the system is also capable of reporting the end of scanning session to a user through a user-defined peripheral device or devices so that the user can continue or terminate the scanning task immediately. Hence, machine idle time is reduced. The peripheral devices for reporting the end of a scanning session to a user can be a sound card capable of emitting a sound, the loudspeaker inside a computer system, a network card inside a computer system capable of sending electronic mail to a user's mailbox, or a data recorder capable of dialing a user's telephone number, pager number or mobile telephone number. FIG. 1 is a flow chart showing the steps carried out in an end-of-scanning reporting system according to this invention. In step 10 , before a user begins some scanning task, the computer makes a quick search for all the peripheral devices available for reporting end-of-scan to the user. The purpose of making such a search is to ensure that the desired reporting device or devices are present. In step 20 , a suitable peripheral device or devices for reporting the end of scanning session are selected. In general, the most convenient method of reporting is chosen. For example, sound may be broadcast from a sound card or from the on-board computer loudspeaker. Alternatively, the end of scanning notice may be e-mailed to a pre-specified user mailbox. In some cases, a digital data recorder may be used to dial a telephone number, a mobile telephone number or a pager number to notify the user. The scanning task is conducted in step 30 . The scanning task includes scanning a single page or a number of pages using an automatic paper feeder. After the scanning operation, the pre-selected peripheral device or devices are activated to report the end of a scanning session in step 40 . After reporting the end of a scanning session, the system must make a conditioned return. In step 50 , the system detects whether there is a scanning task waiting. If there is a scanning task pending, the system jumps back to step 20 where the available peripheral devices are again detected. Otherwise, if no scanning task is waiting, the system terminates. In summary, one major advantage of this invention is the utilization of existing peripheral devices to report the end of a scanning session to a user. Through the notification made by the peripheral devices, the user is able to activate the next scanning task quickly so that idle time of the scanner is greatly reduced. It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.
A reporting system capable of reporting the end of a scanning session to a user through existing computer peripheral devices is proposed. By reporting at the end of a scanning session, the user can proceed with subsequent scanning operations with no delay. Hence, idle time of the scanner is greatly reduced.
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[0001] This application claims priority to U.S. provisional application 60/612,964 filed Sep. 24, 2004. TITLE TOWER SUPPORT SYSTEM FOR IRRIGATION SYSTEM FIELD OF TECHNOLOGY [0002] This description relates to irrigation systems. In particular, this description relates to novel support systems for swing arm support towers for automated irrigation systems. BACKGROUND [0003] Historically, farmers in all areas of the world have used irrigation to increase the number and types of crops that can be grown. Irrigation has allowed arid, unproductive land to be turned into fertile farm land. Flood irrigation was the original type of irrigation. To irrigate by flood, a river or stream was diverted from its natural bed and into the farm ground. More recently farmers have become conscious of the cost and scarcity of water. Because of water scarcity sprinkler irrigation has become a popular type of irrigation. [0004] In early sprinkler irrigation systems the individual pipes had to be moved manually. Now, because of labor costs and other difficulties associated with moving pipes, automated irrigation is rapidly becoming the favored form of sprinkler irrigation. [0005] One widely used automated irrigation system is commonly known as a “pivot” or “pivot sprinkler system.” A pivot sprinkler system has a main arm extending outward from a center pivot structure. The main arm generally comprises a series of pipe sections, that transport water. The pipe sections hold sprinkler heads configured to deliver the water to the field. Each pipe section of the main arm is supported by a tower. The towers are generally supported by two powered wheels. As these wheels turn, the main arm rotates about a central pivot structure. Water is supplied to a fixed inner end of a pipe section and distributed to the sprinklers placed along the pipeline. As the main pipeline section moves about its central pivot structure it irrigates a circular portion of the field. [0006] These automated irrigation systems move in a circular pattern, and because of this, the corners of square fields are not watered by the irrigation system. [0007] To address this short coming, automated irrigation systems have been recently fitted with a steerable swing arm. The irrigation systems are guided by a computerized system that can determine the location of the irrigation system in the field. When the computer determines that the main pipe section of the automated irrigation system is approaching a corner, the steerable swing arm swings out into the corner of the field and irrigates the corner. This guidance is assisted typically by guidewires or markers buried in field that inform the computer of the position of the pivot system in the field. [0008] While this swing arm is effective for watering in the square corners, the swing arm is ineffective in many aspects. These swing arms have a corner tower that is supported by two shafts each riding on a single wheel. This configuration places considerable pressure on the wheel, which usually results in deep ruts in muddy, irrigated fields. As the pivot irrigation system moves over the field during a growing season, these ruts may grow deeper and deeper. As the ruts grow deeper the wheels are more prone to becoming stuck. Others have attempted to remedy this problem by using a larger wheel so that the ground pressure from the tower is lightened, but tires for these large wheels are scare and therefore installation and replacement are expensive. Moreover, the width of a single tire is of little importance if that single tire has become stuck. [0009] When the wheels of the swing arm become stuck, the rest of the irrigation system, nonetheless, may continue across the field causing the irrigation system to bend, break, or tip over. Even if the stuck wheel is discovered, or the pivot system shut of, before the system is damaged, it can be difficult to remove a pivot wheel that has become stuck. Such removal often requires many man-hours and heavy or specialized equipment. This equipment moreover can crush or damage crops or the irrigation system. Frequently, it is necessary to allow the field to dry before attempting to remove a stuck wheel. During certain times of the year crops are very susceptible to drought and may be damaged while allowing the field to dry sufficiently. This damage may result in a reduced, or non-existent crop yield. [0010] An additional problem with current systems is that considerable force and torque can be applied to the support wheel of the swing arm by the weight of the water pipes. This torque can cause the axel or drive shaft that supports the wheel to bend or break. Such damage to the swing arm will be costly to repair and may result in significant down time. [0011] Accordingly, it would be an advantage to provide a swing arm support system that would minimize the depth of ruts formed in a field. It would be an additional advantage if the support system was less susceptible to bending or breakage. It would be an additional advantage to provide a solution that could be retrofitted to current corner swing arm support towers. It would be an additional advantage to use commonly produced parts that could be used interchangeablely with other parts commonly used in irrigation systems. SUMMARY [0012] The present technology provides a support system for a swing arm of an automated irrigation system. In one general aspect, a swing arm support system may include an upper sleeve section and a joint flange that is pivotally connected to the support tower of the swing arm. The upper sleeve section and joint flange can be connected to a hub to which two or more drive wheels are attached. The two or more drive wheels can be configured so that each has a means for driving the wheels. The means for driving the wheels may include a motor and a gear box. [0013] In another general aspect, a swing arm support system may include a single integrated sleeve and hub that is pivotally connected to the support swing arm. Two or more drive wheels are attached to the integrated sleeve and hub. The two or more drive wheels can be configured so that each has a means for driving the wheels. The means for driving the wheels may include a motor and a gearbox configuration, such as a sprocket and a chain. [0014] In another general aspect, a swing arm support system may include an upper sleeve section and a joint flange that is pivotally connected to the support tower of the swing arm. The upper sleeve section and joint flange can be connected to a hub to which two or more drive wheels are attached. The two or more drive wheels can be configured to have a driving means. The means for driving the wheels may include a motor and a single gear box, such as a differential or double shafted gearbox. [0015] In another general aspect, a swing arm support system may include an upper sleeve section and a joint flange that is pivotally connected to the support tower of the swing arm. The upper sleeve section and joint flange can be connected to a hub to which two or more drive wheels are attached. The two or more drive wheels can be configured to have a driving means. The means for driving the wheels may include a single axle passing through the hub. The axle may be turned by a motor and have a gearbox configuration such as a sprocket and chain. BRIEF DESCRIPTION OF THE DRAWINGS [0016] A more particular description of the technology briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. These drawings depict only typical embodiments of the technology and are not therefore to be considered to be limiting of its scope. The present technology will be described and explained with additional specificity and detail through the use of the accompanying drawings. [0017] FIG. 1 illustrates a schematic view of an automated irrigation system. [0018] FIG. 2 illustrates a schematic view of a swing arm support tower and swing arm support system in accordance with the present technology. [0019] FIG. 3 illustrates a schematic view of a swing arm support tower and swing arm support system in accordance with the present technology. [0020] FIG. 4 illustrates a schematic view of a swing arm support system in accordance with the present technology. [0021] FIG. 5 illustrates a schematic rear view of a swing arm support system in accordance with the present technology. [0022] FIG. 6 illustrates a schematic side view of a swing arm support system in accordance with the present technology (shown without wheels, gearboxes, shafts, drivelines, or motors). [0023] FIG. 7 illustrates a schematic front view of a swing arm support system in accordance with the present technology (shown without wheels, gearboxes, shafts, drivelines, or motors). [0024] FIG. 8 illustrates a schematic bottom view of a swing arm support system in accordance with the present technology (shown without wheels, gearboxes, shafts, drivelines, or motors). DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS [0025] The presently preferred embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the system, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations without departing from the spirit of the claims. Thus, the following more detailed description of the embodiments of the apparatus, system, and method of practicing the disclosed technology, as represented in FIGS. 1-8 , is not intended to limit the scope of the claims, but is merely representative of the presently preferred embodiments. [0026] Referring to FIG. 1-8 , a center pivot irrigation system 10 is presented. FIG. 1 shows a schematic view of a pivot irrigation system 10 . The pivot irrigation system 10 includes a tower support system 12 . The irrigation system 10 comprises a plurality of pipe sections 14 a - 14 f that are supported by a plurality of towers 16 a - 16 f. Pipes 14 a - 14 f and towers 16 a - 16 f of irrigation system 10 are generally configured to rotate about a pivot point 18 . Water is supplied to irrigation system 10 at pivot point 18 through the use of underground pipes (not shown). [0027] Each tower 16 a - 16 f has a set of drive wheels 20 a - 20 f that are configured to rotate forward and backward. Drive wheels 20 a - 20 f are not configured to turn right or left. As drive wheels 20 a - 20 f rotate, irrigation system 10 travels in a circular pattern about pivot point 18 . Irrigation system 10 includes a swing arm 22 that includes one or more sections of pipes to move out into a corner 24 of a field 26 . Thus, corner 24 can be watered by swing arm 22 . [0028] With continued reference to FIG. 1 , irrigation system 10 is preferably controlled by an automated guidance system (not shown) that is configured to calculate when irrigation system 10 reaches corner 24 of field 26 . The automated guidance system computer (not shown) then activates a steering mechanism (not shown) on swing arm 22 , and swing arm 22 drives into corner 24 . Such automated guidance systems are known in the art and generally comprise a computer (not shown) and guidance lines (not shown) or guidance points (not shown) buried in field 26 . The guidance lines are used by the computer to determine the position of irrigation system 10 in field 26 . [0029] Turning now to FIGS. 2-7 . In one preferred embodiment tower support system 12 supports swing arm tower 32 . Tower 32 has two insert members 34 a, 34 b extending downward and perpendicular from a horizontal member 36 of tower 32 . The bottoms 38 a, 38 b of insert members 34 a, 34 b contains a ball coupler (not shown) to receive a tow ball 40 . An upper connection sleeve 42 , a jointing flange 44 , and a support hub 46 are connected together to form support system 30 . Upper connection sleeve 42 has a lower flange 48 . Support hub 46 may have a support hub flange 50 . One preferred method of connecting upper connection sleeve 42 to support hub 46 is by bolting together lower flange 48 , jointing flange 44 and support hub flange 50 . Another preferred method of connecting upper connection sleeve 42 to support hub 46 is by welding together lower flange 48 , jointing flange 44 and support hub flange 50 . [0030] In some implementations support system 30 may be pivotally attached to tower 32 by placing insert members 34 a, 34 b into upper connection sleeve 42 and connecting the ball coupler to tow ball 40 . This allows swing arm support system 30 to rotate about insert members 34 a, 34 b. An upper flange 52 of upper connection sleeve 42 is attached to the existing steering mechanism (not shown) of swing arm 22 . The swing arm support system 30 is steered into corner 24 of field 26 by the steering mechanism of irrigation system 10 and drive swing arm 22 . In another embodiment, support system 30 may also be attached through the use of ball bearings attached between insert members 34 a, 34 b and upper connection sleeve 42 . [0031] Particular implementations may include making upper connection sleeve 42 of swing arm support system 30 from tubular shaft material. Such a shaft is typically constructed of a section of tubular metal such as steel or aluminum. Galvanized steel being the most preferred material. Jointing flange 44 , lower flange 48 , support hub flange 50 , and upper flange 52 are generally made from steel plate or other suitable material. Preferred steel plate thicknesses generally range from about 0.25 inches to 1.5 inches, although these thicknesses may increase or decrease depending upon the particular material properties. [0032] In certain implementations, support hub 46 presents gearbox plates 54 a, 54 b for two drive wheels 56 a, 56 b. Drive wheels 56 a, 56 b can be configured to rotate in a forward and a backward direction. While drive wheels 56 a, 56 b are shown in a single wheel configuration having 2 wheels total, it is of another preferred embodiment that the wheels be configured as dual wheels (4 wheels total), triple wheels (6 wheels total) or even more wheels per side as the end user prefers or requires. Additional wheels result in increased surface contact, which reduces pressure on the ground and the crops. Another embodiment allows for the use of wider wheels to further increase the surface contact of the wheel. An additional embodiment allows for the wheels to be removed and a movable track to be used as the ground floatation means. Movable tracks are a common means of ground floatation for tanks, tractors, and other machines that require a large surface contact area. [0033] Embodiments having at least two drive wheels 56 a, 56 b provide a number of advantages. Two drive wheels 56 a, 56 b disperse the weight of water-filled swing arm 22 over a larger area, which increases the flotation of the swing arm 22 , thereby reducing the depth of ruts. Shallower ruts accordingly lessen the likelihood that irrigation system 10 will become stuck in field 26 . [0034] Current systems are generally supported by a hub that is configured to create a single attachment point for a drive wheel. Because of this configuration, the hub maybe weakened by the considerable torque that is applied to the axel or shaft of the wheel. This torque may damage or break the shaft. The double wheel configuration of the present support system provides a more uniform distribution of weight on both wheels 56 a, 56 b with little or no torque being applied to shafts 58 a, 58 b. [0035] Two drive wheels 56 a, 56 b also provide additional traction and power. If swing arm 22 encounters a deep rut or a muddy area in field 26 , loss of traction by a single wheel will be countered by the second wheel, thereby preventing the entire irrigation system 10 from becoming stuck in the rut or mud. [0036] In one preferred embodiment wheels 56 a, 56 b can be operablely connected to support hub 46 by a shaft 58 a, 58 b. One embodiment for wheels 56 a, 56 b is the use of standard automated irrigation wheels (see 20 a - 20 f ). Shafts 58 a, 58 b may be operablely connected to gearboxes 60 a, 60 b that are powered by operablely connected motors 28 a , 28 b. One preferred means of connecting the gearboxes 60 a, 60 b to the motors 28 a, 28 b is with drivelines 62 a, 62 b. Gearboxes 60 a, 60 b may be selected from standard automated irrigation gearboxes of known systems. Known gearboxes are commonly used by automated irrigation manufactures such as Valley® and Reinke® to connect and drive wheels 20 a - 20 f. [0037] Motors 28 a, 28 b can be center-drive motors and can be mounted on a lower connection unit 64 . Lower connection unit 64 has two motor mounts 66 a, 66 b and is connected to support hub 46 . Lower connection unit 64 and motor mounts 66 a, 66 b may be generally constructed of steel, aluminum or other suitable material. Galvanized steel being the most preferred. Alternatively, motor mounts 66 a, 66 b can be created as an integral part of lower connection unit 64 . For example, lower connection unit 64 may be box steel, which would provide flat surfaces for mounting motors 28 a, 28 b . Alternatively, lower connection unit 64 may be custom fabricated in any manner known to those in metal or material fabrication to present a connection unit having the ability to support a motor or motors. Motor mounts 66 a, 66 b support two independent motors 28 a , 28 b that supply power to gearboxes 60 a, 60 b through drivelines 62 a, 62 b. One preferred type of motor for motors 28 a, 28 b is a one-half horsepower electric center-drive motor. [0038] Another preferred embodiment of mounting the motors allows for the use of an angle drive motor. In this preferred embodiment, lower connection unit 64 is removed and angle drive motors are mounted directly, and on opposing sides, to support hub 46 and operably connected to a known corner gearbox. The corner gearbox can then be operably connected to wheels 56 a, 56 b. This allows for a more compact configuration, but known angle drive motors generally require more power to operate than known corner gearboxes. [0039] Another preferred embodiment uses a dual-output gearbox, commonly known as a differential, in place of gearboxes 60 a, 60 b. The dual-output gearbox may be operably connected to support hub 46 . A single motor may be attached to either support hub 46 or the lower connection unit 64 and operably connected to the dual-output gearbox via a driveline. Drive wheels 56 a, 56 b are operably connected to the dual-output gearbox. [0040] Another preferred embodiment uses a single axle passing through the support hub 46 with drive wheels 56 a, 56 b attached to opposing ends of the axle. The axle has an attached gearbox means for rotating the axle, such as a gear sprocket. A motor may have a drive sprocket to allow the motor to be operably attached to the support hub 46 . The gear sprocket and the drive sprocket can be operably attached using a means such as a chain. [0041] If wheels 56 a, 56 b become flattened or require replacement, support hub 46 may be jacked-up and wheels 56 a, 56 b may be replaced. This creates an advantage over known systems, where for a single wheel to be repaired, the entire support tower requires lifting by heavy equipment. [0042] Support hub 46 may be constructed and arranged in any manner that allows for the attachment and operation of at least two wheels on opposing sides of the support hub. Referring to FIGS. 4-8 , one embodiment of support hub 46 may be comprised of braces 68 a - 68 d secured to a lower member 70 . Braces 68 a - 68 d can be attached to lower member 70 through a number of means known in the art such as welding, or bolting, or may be manufactured as a integral part of support hub 46 . For small scale production, the preferred means is welding. Gearbox plates 54 a, 54 b are connected to the braces 68 a - 68 d on the right lateral and left lateral of the lower member 70 . A bottom plate 72 is attached to the bottom of the lower member 70 to provide support to gearbox plates 54 a, 54 b. [0043] Particular implementations may include lower member 70 of support hub 46 generally being made of a tubular shaft. Such a shaft is typically constructed of a section of tubular metal such as steel or aluminum. Galvanized steel being the most preferred material. Braces 68 a - 68 , gearbox plates 54 a, 54 b, and bottom plate 72 may be generally made from steel plate or other suitable material. Galvanized steel being the most preferred. Preferred steel plate thicknesses generally range from about 0.25 inches to 1.5 inches, although these thicknesses may increase or decrease depending upon the particular material properties. It is well known by those individuals familiar with metal fabrication that galvanized steel is not easily welded. Therefore, the construction of embodiments is generally known to be first constructed using a common, weld-friendly steel and subsequently galvanized. [0044] In the illustrated embodiments, tower 32 is a standard commercially available tower. Other designs of commercially available towers exist and swing arm support system 30 can be retrofitted to fit such commercially available towers. It is also anticipated that support system 30 can be configured or modified to be readily attached to other support systems.
A swing arm support system for automated irrigation systems has a support hub and a means to attach and operate two wheels to opposite sides of the support hub. The support hub provides greater ground flotation to prevent the forming of ruts in a field and traction to prevent an automated swing arm from becoming stuck. The swing arm support system provides for the use of common automated irrigation components so that fabrication, repair and operation are most efficient. The support hub in pivotally attached to an existing swing arm support tower. The support hub is carried by two pneumatic tires in one embodiment, four tires in another embodiment, six tires in another embodiment, and movable tracks in another embodiment.
0
FIELD AND BACKGROUND OF THE INVENTION The present invention relates generally to the field of quilts and quilted or quilt fabrics (collectively called quilts here), and in particular to a new and useful process for giving a whole cloth quilt and whole cloth quilt fabrics a vintage or antique appearance, and to the new and useful quilt product itself. Whole cloth quilts are defined as single panels of fabric or fabrics that have been seamed to produce the effect of a single panel on both the top and bottom surfaces of the quilt, and an intermediate layer of batting fabric between the two panels. The stitching of the quilt can be hand-done or machine-made with the effect of forming a sculptured outline of designs caused by the stitching pattern and the puffing of the batting underneath the fabric as it is confined to the spaces between the stitches. There is a long history of whole cloth quilting in America, as it was one of the first quilting styles brought to this country. The original fabrics used in the 18 th century were wool for everyday or white cotton and white linen for more formal use. There was a renewal of interest in whole cloth quilts in the early twentieth century due to the growth in popularity of the sewing machine during that time period, and cotton sateen fabric was often used. Excellent short articles on whole cloth history can be found on the Internet at: www.womenfolk.com/quilting_history/wholecloth.htm and www.quilthistory.com/dating_quilts.htm. Today, whole cloth quilts are stitched by hand or machine using cotton, linen, silk, wool, polyester or blends of any of these fibers. Many of these quilts are marketed with the puffed, sculptured effect of the stitch patterns as the primary appearance feature. Some of the quilts, after they are sewn, also undergo a finishing method to achieve a vintage look. The most popular method is for quilts using 100% cotton batting to be machine washed and dried. This method achieves a puckering of the fabric. The puckering is primarily due to the shrinkage of the cotton batting within the sewn space. With this process, the original smooth and sculptured effect is modified with a puckering giving a different appearance to the quilted fabric. Therefore, there are two different types of whole cloth quilt appearances with each look having its own proponents—the puffed, sculptured effect vs. the puckered effect. An example of a whole cloth quilted sculptured look modified by the puckered effect in quilts can be seen in FIG. 1 which is a partial and schematic illustration of a pattern for a whole cloth quilt that can be antiqued according to the present invention. Patents that are relevant to the present invention include U.S. Pat. No. 4,690,084 for Production of Puffed Embroidered Design Fabrics, U.S. Pat. No. 4,688,502 for Puffed Embroidered Design Fabrics, U.S. Pat. No. 6,702,861 for a Process for Antiquing Fabric, U.S. Published Patent Application 2003/0196276 for a Process for Antiquing Fabric, U.S. Published Patent Application 2002/0133261 for a Method and System for Producing Garments Having a Vintage Appearance, and U.S. Pat. No. 5,759,210 to Potter, et al. for a Lyocell Fabric Treatment to Reduce Fibrillation Tendency. SUMMARY OF THE INVENTION It is an object of the present invention to provide a process for antiquing a quilt which artificially makes the quilt appear faded and worn, and the quilt itself. The term “quilt,” as used here is meant to include quilt fabrics and quilted fabrics that may be used alone or combination with other quilt or quilted fabrics to make a completed quilt. Also within the meaning of the term “quilt,” as used here, are any and all quilted fabrics that can be used to make other products such as jackets, shirts, pants, skirts, robes, dresses, hats, and other types of apparel that utilize textile fabrics that can be sewn into a finished garment, handbags, tote bags, luggage, overnight bags, duvet covers, comforters, shams, bed skirts, fitted and unfitted furniture covers for all types of furniture, tablecloths, placemats, napkins, window treatments, decorative throws, decorative pillows, toys, stuffed toys, laundry bags, diaper bags, laptop bags, cosmetic bags, soft furniture, and scarves. Accordingly the process includes providing a first fabric panel comprising a first selected fiber, a second fabric panel comprising a second selected fiber and a batting panel comprising a third selected fiber. At least the first fabric panel is colored, e.g. piece dyed, yarn dyed, printed or otherwise pigmented in solid color or pattern and/or has some pigment applied in a finishing process as opposed to being in a griege goods state and/or the color was applied to the yarn prior to weaving, and at least the first selected fiber is susceptible to damage, e.g. fading and/or wear, by some aspect of washing, such as wetting and/or abrasion and/or heating. The selection of such a fiber which normally should not be washed, in a quilt which is washed, unexpectedly produces the useful result of the invention, namely the antique effect. The process includes layering the three panels and stitching them along a stitch pattern to form a whole cloth quilt which is then washed in a wet bath and with heat and agitation to cause at least the first fabric panel to wear and fade and then drying the quilted fabric to form a quilt and/or quilted fabric with antique appearance. The inventive process may also include the first and second selected fibers being susceptible to damage by wetting, wherein the first selected fiber includes cellulosic material, preferably rayon, lyocell or blends thereof. The inventive process may also include providing the third selected fiber of the batting to be of a type which shrinks when heated and the washing step including heating the quilt sufficiently to shrink the batting and cause the pattern to contain puckers. The inventive process may also include a washing step including heating the quilt to about 100 to 190 degrees Fahrenheit and agitating the quilt so that surfaces of at least the first fabric panel are rubbed against each other at least 50 times. The antiquing effect of the present invention can be applied to any and all of the puffed sculpted or the puckered or the sculpted and puckered looks. The invention gives an antique appearance of worn and faded fabric to the sculptured look while retaining the puffed, sculptured features. This can be achieved, as will be explained in greater detail later in this disclosure, when polyester batting is used as there is no batting shrinkage forming puckering although there can be minor puckering due to the occasional shifting of the polyester batting within the stitch lines but this is much less puckering than with cotton batting and the whole cloth quilt fabric still retains the puffed, sculptured appearance. The antiquing effect of the present invention can also be applied to the current vintage process achieved by puckering, to improve and enhance the vintage qualities by adding the worn and faded features to the puckered effect. The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: FIG. 1 is a schematic plan view of part of a whole cloth quilt of the invention that has been subjected to the process of the invention; FIG. 2 is a flow chart illustrating the process of the present invention; FIG. 3 is a representation of part of a whole cloth quilt of the present invention which better illustrates the puckering effect; FIG. 4 is a representation of part of a whole cloth quilt of the present invention which better illustrates the sculpturing effect; and FIG. 5 is a composite representation of a control fabric next to a treated fabric according to the present invention, in actual size at the top and in two magnifications at the center and bottom, to illustrate the advantageous effects of the invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawings, FIG. 1 shows part of a whole cloth quilt 10 , having a top fabric panel 12 meant generally to be viewed more often, a bottom fabric panel 14 generally meant to be viewed less than the top panel, intermediate batting 16 , and a pattern of stitches 18 forming sculptured effects 22 and for connecting the three layers to each other. Special care is taken at the out edge 28 of the quilt 10 to insure that the surface panels 12 and 14 are directly engaged with each other along the outer edge to prevent any batting being visible at the edge, and to insure that the batting panel 16 is also secured to both surface panels. Scale 20 having one inch increments shown, appears on quilt 10 in FIG. 1 to indicate the scale of the stitch pattern 18 . Top fabric panel 12 at least, and perhaps bottom fabric panel 14 also, is dyed, printed, pigmented or otherwise colored containing or carrying in a solid color or in a print or pattern. This characteristic of one or both surface fabrics, here simply called colored, can be vivid or bright or pale and has been applied to the griege goods or applied to the yarns before weaving and/or printed on a dyed or prepared-for-print fabric, before the quilt is washed, but is artificially faded by the inventive process as will be explained later. The purpose of the invention is to achieve an antiqued finish on such whole cloth quilt fabrics. The antiqued effect is a worn and/or faded appearance of the top surface fabric 12 or of both surface fabrics 12 and 14 of the quilt. With references to FIG. 2 , the process is as follows. Step 1: The three panels 12 , 16 and 14 are layered on each other, with the batting layer 16 between the top and bottom surface fabrics 12 , 14 as shown in box 24 in FIG. 2 . Consideration 1—Fiber content of surface fabrics 12 and 14 : The following table gives the colorfastness, wet strength, abrasion resistance and dimensional stability properties of certain fibers subjected to commercial wash/dry cycles. Research by the inventor shows that the present invention works best with rayon and rayon blends that exhibit the damage properties to a satisfactory extent, namely they have very low wet strength and low abrasion resistance (causing wear) and largely due to the nature of the fiber and the dyes attraction to the fiber, the abrasion on the surface and the loss of the finish-sizing, among others, they are subject to fading during the laundering process. The types of dyes, the dye application methods and print methods that are used will also effect the loss of color. Although a high degree of shrinkage for the batting may also be useful to achieve puckering, the shrinkage property is not always needed or significant, depending on the type of appearance desired. In addition to rayon and rayon blends, lyocell, also a cellulosic fiber, and lyocell blends exhibit the faded and worn qualities. The lyocell fiber fibrillates when it is washed and agitated. This splintering of the fiber on random areas of the surface causes a faded and worn effect. The desired effect is most prevalent in lyocell fabrics that have not been chemically treated to prevent or reduce fibrillation. TABLE 1 Fiber Properties related to this Invention Abrasion Dimensional Colorfastness* Wet Strength** Resistance*** Stability**** NATURAL Cellulosic Cotton Moderate High Moderate Moderate Linen Moderate High Moderate Moderate Protein-based Silk Moderate Low Moderate Low Wool Moderate Low Moderate Low Cellulosic ManMade Viscose Rayon Moderate Low Low Low Lyocell Moderate Moderate Low Moderate Acetate Moderate Moderate Moderate Moderate SYNTHETIC Polyester Moderate High High High Nylon Moderate High High High Acrylic High High Moderate High Definition of Properties- Colorfastness* The resistance of a dyed and/or printed fabric to fading, in this case during commercial laundering. Wet Strength** The strength of a fabric when it is saturated with water, in this case during commercial laundering. Abrasion Resistance*** The ability of a fiber or fabric to withstand surface wear and rubbing, in this case during commercial laundering. Dimensional Stability**** The ability of a fabric to maintain its original width and length and configuration, in this case during commercial laundering. TABLE 2 These results were obtained after 1 time through the commercial wash/dry process described in the application. Although the effects increase after each time processed, the change is much less significant after the first time. The process of the invention can achieve the desired results through up to 10 wash/dry cycles while prior art quilts and methods achieve some antiquing effect only after 20 or more wash/dry cycles. QUILTED FABRIC TEST RESULTS Quilt Quilt Quilt Top Average Quilt Quilt Quilt top Quilt top Top Top Surface Water Quilt Top Bottom Batting Length Width Fade Wear Dimension Smp Temp Fiber Fiber Fiber Shrinkage % Shrinkage % Grade Grade Grade 1 140 Rayon Rayon Cotton −6.98 −13.95 2 3 4 2 140 Rayon 60S/40R Cotton −6.98 −11.63 2 3 3–4 3 140 Rayon Linen Cotton −4.65 −6.98 2 3 4 4 140 Rayon Rayon Poly −4.65 −6.98 2 3 2 5 140 Bemberg Bemberg Cotton −4.65 −6.98 2 4 4 6 140 Bemberg Bemberg Poly −4.65 −6.98 2 4 1 7 140 Rayon 50R/50L Cotton −6.98 −9.30 3 3 4 8 140 50R/50L Rayon Cotton −9.30 −9.30 3 4 5 9 140 Rayon 85L/15R Cotton −6.98 −13.95 2 3 4 10 140 85L/5R Rayon Cotton −4.65 −13.95 2 4 4 11 140 50R/50L 50R/50L Poly −11.63 −2.33 4 4 2 12 140 Rayon Silk Cotton −6.98 −4.65 2 4 4 13 140 Rayon Silk Cotton −9.30 −6.98 2 2 4 14 140 Rayon 52C/48R Poly −4.65 −11.63 2 3 1 15 140 Linen Rayon Cotton −6.98 −6.98 1 2 3–4 16 140 Cotton Rayon Cotton −4.65 −4.65 1 1 4 17 140 Cotton Cotton Cotton −4.65 −6.98 1 1 4 18 140 Linen Linen Cotton −6.98 −4.65 2 2 5 19 140 Silk Rayon Cotton −6.98 −9.30 1 1 4 20 140 60S/40R 60S/40R Poly −4.65 −4.65 2 2 1 21 140 60S/40R 60S/40R Cotton −4.65 −6.98 2 2 4 22 140 85R/15L 50R/50P Cotton −4.65 −4.65 3 3 2 23 140 50R/50P 85R/15L Cotton −2.33 −2.33 2 4 4 24 140 Silk Silk Cotton −6.98 −13.95 1 2 4 25 140 Silk Silk Cotton −9.30 −6.98 1 1 4 26 140 Silk Rayon Cotton −6.98 −11.63 1 2 3 27 140 85C/15R Cotton Cotton −4.65 −6.98 2 3 4 28 140 Cotton 85C/15R Cotton −4.65 −6.98 1 1 4 29 140 50R/50P 50R/50P Poly −6.98 −11.63 2 3 1 30 140 50R/50P 50R/50P Cotton −9.30 −11.63 2 3 3 31 140 85C/15R Rayon Cotton −6.98 −11.63 2 4 4 32 140 52C/48R Cotton Cotton −4.65 −6.98 2 2 4 33 140 52C/48R Rayon Poly −4.65 −11.63 2 4 1 34 140 52C/48R Rayon Cotton −4.65 −11.63 2 4 4 35 140 70S/30R Rayon Cotton −6.98 −11.63 2 3 3 36 140 80R/20W 80R/20W Cotton −6.98 −6.98 2 4 4 37 140 80R/20W 80R/20W Poly −6.98 −6.98 2 4 2 38 140 Wool Wool Cotton −11.63 −6.98 1 2 4 39 140 Wool Wool Poly −11.63 −6.98 1 2 1 40 140 Acetate Acetate Cotton −6.98 −2.33 2 1 3 41 140 Acetate Acetate Poly −2.33 −2.33 2 1 2 42 140 Lyocell Lyocell Cotton −2.33 0 2 3 4 43 140 Lyocell Lyocell Poly −2.33 −2.33 2 3 2 44 140 Acrylic Acrylic Cotton −2.33 −2.33 1 2 4 45 140 Acrylic Acrylic Poly 0 0 1 2 2 46 140 Lyocell Lyocell Cotton −2.33 −2.33 2 3 4 47 140 Lyocell Lyocell Cotton −2.33 −2.33 2 3 4 48 140 60L/40R 60L/40R Cotton −4.65 −4.65 2 3 4 Tests were conducted to determine the fading, wear and surface dimension of quilted fabrics. The AATCC-American Association of Textile Chemists and Colorists test methods were used as guidelines for conducting these tests to obtain accurate and reliable results, specifically, AATCC Test Method 61-2003. Colorfastness to Laundering, Home and Commercial: Accelerated and AATCC Test Method 96-2001 Dimensional Changes in Commercial Laundering of Woven and Knitted Fabrics except Wool. These AATCC tests are not meant to be used for quilted fabrics and the Colorfastness test is an accelerated test. They have been used as guidelines only, to provide the best possible procedures considering the differences in their usage with this test. The quilted samples were sewn 8″×8″ consisting of a top fabric, bottom fabric and inner layer of batting. The squares were sewn in a grid quilt pattern using ½″, 1″ and 1½″ spacing of the quilt lines to provide variation in distances between the quilt lines. Bench mark lines made with a template were drawn with a marking pen on each side of the quilted sample to be later used for measuring quilt shrinkage. Samples were laundered in a commercial washer on Cotton/Sturdy cycle at a temperature of about 140 degrees F. The samples were washed together at one time so that the load weighed about 3 lbs to provide sufficient friction of fabrics against each other. A detergent was used in an amount indicated for normal washing that is similar in content to the AATCC Standard Reference Detergent—Without Optical Brighteners—so that it would not interfere with the color change. The total running time of the washing was about 30 minutes including wash cycle and fill time. The quilted samples were dried in a commercial dryer—Tumble Dry—Cotton/Sturdy cycle at about 160 degrees F. for about 30 minutes until all samples were completely dry, with the cotton batting samples taking longer than the polyester batting samples to dry. The samples were then graded on a 1–5 scale compared to the control samples that were not laundered. Grading System: Fade—Degree of Color Change 1—No change in color 2—Minimal change in color 3—Moderate change in color 4—Heavy change in color 5—Very Heavy change in color. Wear—Surface Attributes—One or More of: short fiber ends, hairy, uneven thinning, irregular texture, scoffed, and stippled 1—No change in surface fibers 2—Minimal change in surface fibers 3—Moderate change in surface fibers 4—Heavy change in surface fibers 5—Very Heavy change in surface fibers. Surface Dimension—Contours of the surface fabrics 1—Full, puffed surface 2—Slight puffed surface 3—Moderately flat surface 4—Moderate dense, rippled surface 5—High dense, rippled surface. The natural fibers of cotton and linen in their pure form (not blended with rayon) have high wet strength and therefore are not susceptible to fade or wear during the washing process. Pure silk, although it has low wet strength, has medium or moderate abrasion resistance in most of its forms and will show almost no fading or wear during the washing process. The wool tested showed little wear or fading. Fabrics with blends of the natural fibers and rayon or lyocell, all showed a degree of wear and fading to be included in this invention. The same holds for the synthetic fibers. In their pure form, polyester, nylon and acrylic have a high wet strength and therefore cannot be included in this invention. When they are blended with rayon or lyocell, they exhibit degrees of wear and fading on the surface. The minimum amount of rayon or lyocell that needed to be part of the blend for all the fabrics, both natural and synthetic, was 15%, or from 10% to 100% by weight, as a preferred range. In addition, it did not matter if the blended fabric was made from blended yarns or if the fabric was made from a pure fiber warp or weft woven in combination with a pure rayon or lyocell warp or weft. Also, within the designated fiber types, rayon and rayon blends, the degree of wear and fading was related to the way the fibers were spun into yarn, the type of weave and the finishing of the fabrics. Staple fibers, looser weaves, jacquard weaves and minimal finishing resulted in more wear and fading than longer filament yarns, tight weaves, plain weaves, and heavy finishing processes. However, all rayon and rayon blended fabrics showed wear and fading within the grade ranges specified in Table 2. The surface dimension was strongly related to the batting fiber. The cotton batting produced a rippled surface and the polyester batting a smoother, puffed surface. The type of batting did not effect the wear or fading of the surface fabrics. Since the rippled surface is often viewed as a vintage look, this invention will improve and enhance that process. In addition, this invention will also provide a method for antiquing for those who Want to retain the puffed, sculptured look that can be caused by polyester batting stitched in whole cloth quilted fabric. Other cellulosic fibers in addition to rayon and lyocell may also work to achieve the desired extent of antiquing. Rayon is a manufactured but non-synthetic fiber. There are three different types of rayon for apparel and home textiles. The most dominant form, with the largest market share, is called “regular rayon” or “viscose.” It is the regular or viscose rayon that is produced in the most widespread production process that has the properties most applicable to the present invention. The main reasons are that when wet, the rayon fibers are very weak and can break down at the surface when abrasion is applied during the washing process. Also, the fabric loses its luster, sheen and a degree of color, usually from the loss of the sizing that is used in the finishing of the fabric, the nature of the fibers and the effect of abrasion on the surface. Also, the low dimensional stability during washing can contribute to an irregular texture on the fabric surface which has a distressed effect. The two other types of rayon are produced in relatively much smaller quantities—HWM and Cupramonium rayon. HWM can be machine washed and dried and has high wet strength. It is frequently called “polynosic.” Cupramonium rayon has similar properties to regular, viscose rayon, and can be included in this invention. Cupramonium rayon is often referred to under the trademark name of “Bemberg”. 100% Bemberg rayon was included in the test and showed comparable results to the regular, viscose rayon. The object in any case is to select a fabric which contains at least some fiber that is susceptible to damage by some aspect of washing such as wetting and/or agitation, so that the fiber fades or appears worn after washing. The fiber selected thus is of a type which, counter-intuitively, should not be washed, but which the inventor has discovered produces a new, advantageous and unexpected result, namely an attractive vintage or antiqued appearance. According to the present invention the word “damage” means fading or wear or other distress caused by some aspect of washing, such as but not limited to wetting and agitation. Consideration 2—Fiber content of batting: 100% Cotton and 100% polyester batting was tested. Weight of the cotton batting was 200 grams per square meter with batting shrinkage of 3–5%. Cotton batting for this invention will have an average range from about 150–270 grams per square meter but it can be lighter or heavier. The polyester used in the testing was low loft. Both high loft and low loft polyester and any loft of polyester can be used for this invention. Polyester does not shrink and generally causes a lightweight, smooth, puffy surface. The polyester retains the sculptured effect of the quilt pattern of the whole cloth quilted fabric. Although much rarer, wool batting can be used, and the wool batting that is resin bonded can be machine washed and dried without shrinkage, causing a similar appearance to the polyester. The wool batting provides warmth and is lightweight. Wool batting can be used in whole cloth quilted fabric in this invention. Also, silk or rayon or lyocell batting can be used for this invention. Blended fibers such as cotton and polyester blended can be used as batting in addition to any combination of the aforementioned batting fibers. The choice of batting for a quilt or quilted fabric is generally determined by these factors: use of the quilt or quilted fabric, whether it is needed for warmth, desired fiber-natural or synthetic, whether done by machine or hand, distance of stitch lines, and appearance. The type of batting fiber and how it is processed affects its performance during and after the quilting process. Most quilt batting is made with a bonding or a needle-punched process, and either process will produce the desired effect. Batting that is plain or garneted will require the quilt lines stitching in any pattern to be closer together, generally ¼ to 1 inch apart, to prevent bunching or shifting. This applies to all quilts not only to whole cloth quilts or whole cloth quilts with the antiquing process of the present invention. Based on the inventor's research, both cotton batting and polyester batting work for the invention. The surface effects are different but both can be antiqued to the desired appearance. If a “rippled effect” or puckering is also desired in addition to the antiquing, then batting susceptible to shrinkage (meaning cotton or the like, and not polyester) is used. Also, wool, silk, rayon, lyocell and any combination of the fibers can be used. Step 2: The three layers are stitched together by hand or machine with stitching across the surface of the fabrics, illustrated by box 26 in FIG. 2 . The edges of the quilt at 28 in FIG. 1 , must be finished so that the top and bottom panels 12 , 14 are joined together with batting also attached but enclosed between the top and bottom layers so that no batting is visible at the edge. Consideration 1—Length of the stitches: Not less than 6 stitches per inch should be used. An average number of stitches is 10 to 14 stitches per inch and generally 6 to 21 can work with the invention or a higher number based on machine used. The maximum amount must be less than would cause gathering of fabric around the stitch line. If machine stitched, tension must be adjusted so that stitching 18 is smooth. Consideration 2—Fiber content of the thread used for stitching: Cotton thread was used for the test because in general, the thread type should match the fiber content and cotton thread is generally used with cottons, linens, rayons as they are cellulosic and even silks, when silk thread is not available. However, polyester thread can be used in this invention with no anticipated problems, but is not advisable due to the above. Consideration 3—Distance between the patterns being stitched: The closer together the stitch lines 18 in any pattern, the more defined the pattern on the surface fabric 12 as the batting 16 is in a more confined space. Therefore, the stitch lines can be next to each other or apart from each other with the average distance ¼ to 2 inches. Going beyond 4 square inches of space without stitching will diminish the fullness of the sculptured effect because the batting has more space between stitch lines but is still a viable part of this patent application. The distance between the stitch lines in any pattern does not affect the wear or fading of the fabric. Step 3: Washing of the quilt, at 30 in FIG. 2 . The quilt is washed in a commercial washer or can be washed by hand in a temperature ranging from 100 to 190 degrees Fahrenheit. The machine washing cycle is heavy or the longer wash cycle with the most agitation—with the agitator causing abrasion on the wet fabric. If washed by hand, the surface of the fabric must be rubbed against itself a minimum of 50 times. This amount of agitation automatically takes place for machine washing. Testing has confirmed the water temperature and best range. Step 4: Drying of the quilt, at 32 in FIG. 2 . The quilt is machine dried in a commercial dryer on the warm/hot setting. ADVANTAGES OF THE INVENTION The antique or vintage look has gained in popularity as consumers desire items that have a nostalgic feeling. The yearning for products that appear aged by time is a trend that many say will only grow, particularly as the Baby Boomer generation continues to mature. In addition, decorating with antiques and distressed furniture has also increased in popularity and this invention fits and enhances that decorating style and can be a useful product for consumers with that decorating preference. The worn, faded and rippled surface on a whole cloth quilt offers a vintage appeal to a product that has a long history in the United States. It provides a much more authentic vintage look over current processes. The current process provides a puckered look, but the fabric itself can still look new. This invention is an improvement over that process because it also gives an antique appearance to the fabric which makes the item appear more authentically vintage. The invention also allows for different types of surface effects—including the original sculptured, outlined look, depending on the fiber content of and the batting. FIG. 3 illustrates the puckering effect of a whole cloth quilt of the present invention and FIG. 4 illustrates the puffed, sculptured effect. FIG. 5 , upper left section is an actual size image of a quilt of the present invention before it has been subjected to the treatment according to the present invention. The upper right section of FIG. 5 is an actual size image of the quilt after treatment to show the antiqued effect. The middle left and right sections show the same respective control and treated quilts at three times magnification (×3) while the bottom left and right sections show the control and treated quilt images at six times magnification (×6). While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
Process for antiquing a quilt and resulting product includes providing a first fabric panel containing at least some of a first selected fiber, a second fabric panel containing at least some of a second selected fiber and a batting panel containing at least some of a third selected fiber. At least the first panel and its fiber is colored and susceptible to damage by washing. The three panels are layered and stitched together using thread of a fourth selected fiber and along a pattern to form a whole cloth quilt or fabric therefore can be used as is or as material for another product. Washing the quilt in a wet bath and with heat and agitation causes at least the first fabric panel to wear and fade and the quilt is then dried and has the antiqued appearance.
3
CROSS-REFERENCE TO RELATED APPLICATION This is a continuing application, under 35 U.S.C. § 120, of copending international application No. PCT/EP03/04338, filed Apr. 25, 2003, which designated the United States; this application also claims the priority, under 35 U.S.C. § 119, of German patent application No. 102 18 826.2, filed Apr. 26, 2002; the prior applications are herewith incorporated by reference in their entirety. BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to a heat exchanger, such as an evaporator, a condenser, or the like, for a refrigerator with a base plate, a pipeline for a refrigerant, disposed in heat-conducting contact with the base plate, and a layer of holding material, adhering to the base plate and the pipeline. The present invention also relates to a method for producing such a heat exchanger. Such heat exchangers and methods for production are known from German Published, Non-Prosecuted Patent Application DE 199 38 773 A1. In this production method, a pipeline that is bent in a meandering manner is held pressed against a base plate, and the intermediate spaces between the meanders of the pipeline are filled with a holding device. This holding device may be an expanded polyurethane foam or, else, pourable thermosetting plastics. Such holding measures are costly, and the cross-linking that takes place while they are curing or expanding makes it difficult for them to be recovered and reused if such an evaporator is to be recycled. SUMMARY OF THE INVENTION It is accordingly an object of the invention to provide a heat exchanger for a refrigerator and method for producing a heat exchanger that overcome the hereinafore-mentioned disadvantages of the heretofore-known devices and methods of this general type and that provide an inexpensive heat exchanger for a refrigerator that can be easily recycled and a method for its production. With the foregoing and other objects in view, there is provided, in accordance with the invention, a heat exchanger for a refrigerator, including a base plate, a pipeline for holding a refrigerant, the pipeline in heat-conducting contact with the base plate, and a layer of holding material adhering to the base plate and to the pipeline, the layer of holding material being of a bitumen composition. The use of a bitumen composition as the layer of holding material has the advantage, on one hand, that such materials are inexpensively available and, on the other hand, that they can be easily recycled because the bitumen material obtained after breaking up such a heat exchanger into its component parts can be used for producing a new heat exchanger or other purposes without any appreciable reprocessing and without loss of quality. Furthermore, use of the bitumen composition ensures, after it has cooled down, there is an intimate contact of the pipeline with the base plate, whereby the thermal efficiency of the heat exchanger is improved. The mass of the bitumen composition also has a heat- or cold-storing effect, which, in the case of an evaporator, serves the purpose of lowering the energy consumption of a refrigerator. The connection achieved by the bitumen composition between the base plate and the pipeline can be subjected to great mechanical loads and, consequently, the heat exchanger is dimensionally very stable during handling in the production sequence of a mass production operation. The conforming properties of the bitumen composition mentioned makes it follow the exact contours of the pipeline and the base plate. As a result, no moisture can diffuse in between the pipeline and the base plate. Thus, a risk of corrosion or of ice formation leading to detachment of the pipeline from the base plate is avoided. In accordance with another feature of the invention, to promote the heat transfer between the pipeline and the base plate, the pipeline may have a flattened cross-section with a widened side facing the base plate to ensure surface-area contact between the base plate and the pipeline. The surface-area contact ensures heat-conducting contact between the pipeline and the base plate even under unfavorable production conditions. In accordance with a further feature of the invention, the to achieve a firm connection between the layer of holding material and the base plate, a layer of adhesive, which bonds the layer of holding material to the base plate, at least locally may, preferably, be provided. This layer of adhesive, preferably, is of an adhesive that can be activated by heat. This simplifies the production of the heat exchanger because the layer of adhesive can be applied in advance in an unprotected state to a sheet of the bitumen composition used for forming the layer of holding material and because it gains its effectiveness by melting when the layer of holding material is heated. Apart from bitumen, the bitumen composition may contain between approximately 50% and approximately 80% of filler. The filler, which may be a single material or a mixture of materials, may be selected, for example, from the aspect of minimizing costs or improving the thermal conductivity. A preferred filler is powdered stone. In accordance with an added feature of the invention, for protection, the layer of holding material may be provided with a layer of lacquer on its side facing away from the base plate. In accordance with an additional feature of the invention, the layer of holding material expediently has an average thickness in the range between approximately 0.5 and 2 mm, preferably, between approximately 1.0 and 1.5 mm. With the objects of the invention in view, there is also provided a in a refrigerator having a housing, a heat exchanger including a base plate disposed in the housing, a pipeline for holding a refrigerant, the pipeline in heat-conducting contact with the base plate, and a layer of holding material adhering to the base plate and to the pipeline, the layer of holding material being of a bitumen composition. With the objects of the invention in view, there is also provided a method for producing a heat exchanger, including the steps of forming a stack having a base plate, a pipeline for holding a refrigerant, the pipeline being in heat-conducting contact with the base plate, and a sheet of holding material adhering to the base plate and to the pipeline, the sheet of holding material being of a bitumen composition, and heating the sheet and compressing the stack. The production of a heat exchanger of the type described above is possible in a simple way by forming a stack that includes a base plate, a pipeline for a refrigerant, and a sheet of a bitumen composition and by, subsequently, heating the sheet and compressing the stack. In accordance with yet another mode of the invention, the heat exchanger is an evaporator or a condenser. In accordance with a concomitant mode of the invention, the base plate, the pipeline, and the sheet of the bitumen composition are stacked in this sequence. Other features that are considered as characteristic for the invention are set forth in the appended claims. Although the invention is illustrated and described herein as embodied in a heat exchanger for a refrigerator and method for producing the heat exchanger, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. The construction and method of operation of the invention, however, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of an evaporator according to the invention; FIG. 2 is a fragmentary, cross-sectional view through a portion of the evaporator of FIG. 1 ; and FIGS. 3 , 4 , and 5 are fragmentary, cross-sectional views through a portion of the evaporator according to the invention in various process steps for producing the evaporator. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the figures of the drawings in detail and first, particularly to FIG. 1 thereof, there is shown an evaporator constructed from a planar base plate 1 of aluminum sheet. On the sheet is a refrigerant line 2 , including a pipe likewise of aluminum, which is configured in a meandering manner. The base plate 1 and the refrigerant line 2 are covered by a layer 3 of holding material of a bitumen composition. This includes approximately 25% of polymer-modified bitumen, approximately 3% of a polymer, and approximately 72% of powdered stone. As FIG. 2 shows, the refrigerant line 2 does not have an exactly round cross-section, but a flattened cross-section, whereby the refrigerant line 2 and the base plate 1 touch each other with at least approximately surface-area contact. As a result, a heat-conducting contact is achieved between the refrigerant line 2 and the base plate 1 in a simple manner in terms of production. The layer of holding material 3 extends into interstices 4 that lie on both sides of the contact line between the refrigerant line 2 and the base plate 1 . The solid layer of holding material 3 provides a better heat transfer between the base plate 1 and the refrigerant line 2 than would be possible with the conventional use of a polyurethane foam as holding material. The flattened form of the refrigerant line 2 provides a smaller thickness of the layer of holding material 3 in the interstices 4 than would be the case with a round line 2 . This is favorable likewise for an efficient heat exchange between the base plate 1 and the refrigerant line 2 . Between the layer of holding material 3 and the base plate 1 , there is a layer 5 of a hot-melt adhesive, which, because of its much smaller thickness in comparison with the base plate 1 and the layer of holding material 3 , can only be seen as a line in the FIG. 2 . Individual steps of the production of the evaporator according to the invention are represented in FIGS. 3 , 4 , and 5 . In a first method step shown in FIG. 3 , a stack is formed, the layers of which respectively include the base plate 1 , the refrigerant line 2 , and a 1.2 mm thick sheet 6 of the bitumen composition. On the underside of the sheet 6 facing the base plate 1 and the refrigerant line 2 there is the layer of adhesive 5 . Because the adhesive of the layer 5 does not adhere to the sheet in the cold state, the sheet 6 , together with the layer 5 , can be easily prefabricated and handled; measures to protect the adhesive power for the time between production and use of the sheet 6 are not necessary. In the phase of producing the evaporator that is shown in FIG. 3 , the refrigerant line 2 does not yet have to rest on the base plate 1 over its entire length; a slight undulation of the refrigerant line 2 perpendicular in relation to the surface of the base plate 1 , as shown in FIG. 3 , is permissible. In a second step of producing the evaporator that is shown in FIG. 4 , a die 7 is pressed against the upper side of the sheet 6 . In this stage, the sheet 6 is cold and, consequently, rigid; the pressing force of the die 7 has the effect that the refrigerant line 2 is pressed against the base plate 1 over its entire length. The die 7 is provided on its underside, facing the sheet 6 , with channels 9 . The path of these channels 9 corresponds to that of the refrigerant line 2 . As an alternative thereto, the die 7 may also be produced from elastomeric polymer, such as, for example, silicone with a hardness of, for example, 20 Shore A and a material thickness of 20 mm. In the case of a die made of elastomeric polymer with an adapted Shore hardness, so as not to cause the refrigerant line any damage, there is no need for the channel path of the refrigerant hardening to be introduced on the underside of the die. Subsequent heating makes the bitumen of the sheet 6 become free flowing, and the sheet 6 is pressed against the base plate 1 in the intermediate spaces 8 between neighboring portions of the refrigerant line 2 . The viscosity of the bitumen composition is set such that, on one hand, it becomes free-flowing enough to penetrate into the interstices 4 between the base plate 1 and the refrigerant line 2 , but, on the other hand, is still viscous enough to prevent parts of the refrigerant line 2 from becoming re-detached locally from the base plate 1 . To rule out the possibility of local re-detachment of the refrigerant line 2 independently of the free-flowing capability of the bitumen-composition, the channels 9 of the die 7 may also be provided locally with non-illustrated projections that are pressed through the sheet 6 when the latter is heated and come into direct contact with the refrigerant line 2 to keep it pressed against the base plate 1 . The melting point of the hot-melt adhesive of the layer of adhesive 5 is chosen such that it melts during the heating and shaping of the sheet 6 and, therefore, after cooling down, bonds the re-solidified layer of holding material 3 firmly to the base plate 1 and the refrigerant line 2 . The layer of adhesive 5 may extend over the entire underside of the sheet 6 or only over parts of it. For sealing the exposed surface of the layer of holding material 3 , a layer of lacquer, in particular of shellac, may be applied. The recovery of the bitumen composition during recycling of the evaporator is possible in a simple way, in that the layer of holding material 3 , which is brittle in the cold state, is made to come away in pieces by deforming the evaporator or in that the bond between the layer of holding material 3 and the refrigerant line 2 or base plate 1 is made to rupture by extreme cooling of the evaporator, for example, with the aid of dry ice.
A heat exchanger for a refrigerating appliance includes a plate, a conduit tubing, which is placed in thermo-conductive contact with the plate and is provided for transporting a coolant, and a holding material layer that adheres to the plate and to the conduit tubing. The holding material layer is made of a bitumen composition. The heat exchanger can be produced by stacking the plate, the conduit tubing, and a sheet made of the bitumen composition, whereby the holding material layer is formed form the sheet by heating and pressing the stack.
5
RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/325,412, filed on Apr. 19, 2010, the content of which is incorporated herein by reference in its entirety. TECHNICAL FIELD [0002] The present invention generally provides an improved lighting device, and more particularly an improved lighting device of the type commonly used for temporary lighting. BACKGROUND OF THE INVENTION [0003] Flashlights have been long known and widely used. Although simple flashlights have been generally effective for many required applications, such as illuminating small work areas in dimly lit locations with a generally large space envelope surrounding them. However, their abilities are often limited by size. Generally, whenever a larger area of illumination is required, a larger flashlight is required. When a larger flashlight is used, the space envelope around any particular work area is also required. SUMMARY OF THE INVENTION [0004] A collapsible lighting device can solve many of the problems posed by conventional flashlights. Flashlights work well when a relatively small focused area of illumination is needed for a particular work area. They become limited when a wide area of illumination is required, such as the underside of an automobile or behind a piece of equipment for example. As flashlights typically only have one light bulb which is focused by a reflective lens, they typically only illuminate a small area. By utilizing a plurality of light emitting elements, a collapsible lighting device can illuminate a significantly larger work area. [0005] This creates an additional improvement. Flashlights are generally are hard to position and hold in place when aiming the single beam of light at a particular work area. They require precise positioning to illuminate a desired area which can be difficult for a user, and sometimes can be impossible given the space envelope surrounding the work area. As the collapsible lighting device utilizes a plurality of light emitting elements to create a larger area of illumination, they do not require such precise positioning and aiming. [0006] Although large arrays of light emitting elements can provide a larger area of illumination, a very large rigid device would be awkward and difficult to handle by a user. Also, portability and transportation concerns exist. By making the device collapsible, an end user can roll up or fold a large device into a compact and portable form. Then that user would be able to put the device in a tool box or bag and bring it to another work area. Further, collapsible lighting devices are capable of being temporarily expanded to produce a larger array of light, depending on the needs of a user at any particular time. [0007] In addition, to improve on the userability of a lighting device, a collapsible lighting device can be designed to be thin and low profile so that it can be used in tight spaces like under an automobile or between a wall and a large piece of equipment. Further, a collapsible lighting device can be manufactured from flexible materials such that it does not require a large flat surface to be placed on, as often work areas are not conducive to large, flat, stable surfaces. To compliment the thin design, a collapsible lighting device can be designed with mounting tabs and magnets built in to allow for temporary positioning in a variety of applications. [0008] In one aspect, a collapsible lighting device comprises: a plurality of light panel sections, each light panel section comprising a plurality of light emitting elements; at least one connection element constructed and arranged to connect one or more light panel sections of the plurality of light panel sections to one another; and an electronic control system configured to distribute electrical power to the plurality of light emitting elements. [0009] In one embodiment, the electronic control system comprises an on/off switch. [0010] In another embodiment, the electrical power supply comprises a rechargeable battery pack. [0011] In another embodiment, the at least one connection element comprises a rotating hinge. [0012] In another embodiment, the at least one connection element comprises a multi-position rotating joint. [0013] In another embodiment, the at least one connection element comprises a flexible material joint. [0014] In another embodiment, a light panel section of the plurality of light panel sections comprises a base material and a lens material, wherein the plurality of light emitting elements of the light panel section are positioned between the base material and the lens material. [0015] In another embodiment the collapsible lighting device further comprises mounting tabs attached to the light panel. [0016] In another embodiment, the collapsible lighting device further comprises magnetic components for mounting. [0017] In another embodiment, the base material comprises one or materials selected from the group consisting of: rubber, plastic, polyurethane, vinyl, nylon, composite, textile, and metals. [0018] In another embodiment, the lens material comprises one or materials selected from the group consisting of: rubber, plastic, polyurethane, vinyl, nylon, composite, textile, and metals. [0019] In another embodiment, the connection element constructed and arranged to connect one or more light panel sections of the plurality of light panel sections to one another can be decoupled. [0020] In another aspect, a collapsible lighting device comprises: a flexible light panel section that can be rolled up; a plurality of light emitting elements; an electrical power source; and an electronic control system configured to distribute electrical power to the plurality of light emitting elements. [0021] In one embodiment, the flexible light panel section comprises a flexible base material and a flexible lens material, wherein the plurality of light emitting elements of the flexible light panel section are positioned between the flexible base material and flexible lens material. [0022] In another embodiment, the electronic control system comprises an on/off switch. [0023] In another embodiment, the electrical power source comprises a rechargeable battery pack. [0024] In another embodiment, the collapsible lighting device further comprises mounting tabs attached to the light panels. [0025] In another embodiment, the collapsible lighting device further comprises magnetic components for mounting. [0026] In another embodiment, the flexible base material comprises one or materials selected from the group consisting of: rubber, plastic, polyurethane, vinyl, nylon, composite, textile, and metals. [0027] In another embodiment, flexible lens material comprises one or materials selected from the group consisting of: rubber, plastic, polyurethane, vinyl, nylon, composite, textile, and metals. [0028] In another embodiment, the collapsible lighting device comprises light emitting elements which are positioned and directed in opposing directions to allow multi-directional illumination. BRIEF DESCRIPTION OF THE DRAWINGS [0029] The foregoing and other objects, features and advantages of embodiments of the present inventive concepts will be apparent from the more particular description of preferred embodiments, as illustrated in the accompanying drawings in which like reference characters refer to the same elements throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the preferred embodiments. [0030] FIG. 1 is a perspective view of a fully expanded lighting device in accordance with embodiments of the present inventive concepts. [0031] FIG. 2 is a perspective view of an individual light panel in accordance with embodiments of the present inventive concepts. [0032] FIG. 3 is a perspective view of an individual light panel in accordance with other embodiments of the present inventive concepts. [0033] FIG. 4 is a perspective view illustrating a method of collapsing a lighting device in accordance with embodiments of the present inventive concepts. [0034] FIG. 5 is a perspective view illustrating a method of collapsing a lighting device in accordance with other embodiments of the present inventive concepts. [0035] FIG. 6 is a perspective view of a flexible lighting device in accordance with embodiments of the present inventive concepts. [0036] FIG. 7 is a perspective view illustrating a method of mounting a lighting device in accordance with embodiments of the present inventive concepts. [0037] FIG. 8 is a perspective view illustrating a method of mounting a lighting device in accordance with other embodiments of the present inventive concepts. DETAILED DESCRIPTION OF EMBODIMENTS [0038] FIG. 1 is a perspective view of a fully expanded lighting device. A lighting device 100 can comprise one or more light panels 101 each having a plurality of light emitting elements 103 . The light emitting elements 103 of the light panels 103 can be powered by an electrical power source 105 , such as, a rechargeable battery pack comprising one or more individual batteries, a solar power panel, a fuel cell, or an internal electrical generator. In another embodiment, the light emitting elements 103 of the light panels 101 can be powered by AC electrical power. [0039] The lighting device 100 can further comprise an electronic control system 107 that is configured to control the distribution of electrical power to the light emitting elements 103 of the one or more light panels 101 . In one embodiment, the electronic control system 107 comprises a simple on/off operational switch or a control dial. Further, the electronic control system 107 can comprise an LED driver circuit that can manage and distribute electrical power to the light emitting elements 103 . [0040] In one embodiment, the one or more light panels 101 can be connected to one another by hinges 112 . However, in another embodiment, the light panels 101 can be connected to one another by a rotational joint or a flexible material, such as, rubber or plastic. Further, the one or more light panels 101 can be electrically connected to one another by a wire harness 104 . The wire harness 104 can comprise one or more conductors from the group of conductors comprising: ribbon cable, coaxial cable, twisted wire. However, in another embodiment, electrical connections can be built into the hinge mechanism 112 . As such, the wire harness 104 or hinge 112 can distribute electrical power to each of the one or more light panels 101 of the lighting device 100 . [0041] In one embodiment the light panels 101 can be decoupled at the hinges 112 to add or remove light panels from the lighting device 100 . In another embodiment, the light panels 101 can be permanently coupled to one another at the hinges 112 . [0042] FIG. 2 is a perspective view of an individual light panel. A light panel 101 can comprise a plurality of light emitting elements 103 that are positioned between a base material 110 and a lens material 111 . The base material 110 and the lens material 111 can comprise materials that protect inner components from debris and/or damage. The base material 110 can comprise one or more materials selected from the group of materials comprising: metals, plastics, acrylics, composites and glass. The lens material 111 can comprise one or more materials selected from the group of materials comprising: plastics, acrylics, and glass. In one embodiment, the base material 110 and the lens material 111 comprise the same material. Further, the lens material 111 can comprise a translucent material or a transparent material, and the base material 110 can comprise a translucent material, a transparent material, a reflective material or an opaque material. [0043] The light emitting elements 103 can comprise one or more light emitting diodes (LEDs). However, in other embodiments, the light emitting elements 103 can comprise one or more, incandescent lighting elements, fluorescent lighting elements, organic light emitting diodes (OLEDs) or liquid crystal displays (LCDs). [0044] In this exemplary embodiment, electrical power is provided to the light emitting elements 103 of the light panel 101 by a power cord 106 , which can be connected to an external AC electrical outlet. However, in other embodiments, electrical power can be provided to the light emitting elements 103 of the light panels 101 by an electrical power source, such as, the electrical power source 105 in FIG. 1 . [0045] FIG. 3 is a perspective view of an individual light panel. A light panel 101 can comprise a plurality of light emitting elements 103 that can be housed in a rigid chassis 116 . The light emitting elements 103 of the rigid chassis 116 can be covered with a lens material 111 . The light emitting elements 103 can be powered by an electrical power source 105 and can further be controlled by an electronic control system 107 . [0046] The rigid chassis 116 and lens material 111 can comprise a material which has sufficient material properties to protect the inner components from debris and/or damage. The chassis 116 can comprise one or more materials selected from the group of materials comprising: metals, plastics, acrylics, composites and glass. The lens material 111 can comprise one or more materials selected from the group of materials comprising: plastics, acrylics, and glass. In one embodiment, the chassis 116 and the lens material 111 comprise the same material. Further, the lens material 111 can comprise a translucent material or a transparent material, and the chassis 116 can comprise a translucent material, a transparent material, a reflective material or an opaque material. [0047] FIG. 4 is a perspective view illustrating a method of collapsing a lighting device 100 . A lighting device comprising a plurality of light panels 101 can be collapsed according to an accordion-type method, which allows a lighting device 100 comprising two or more individual light panels 101 to be fully collapsed into a stack 150 . [0048] In this exemplary embodiment, a plurality of light panels 101 are connected to one another by hinges 112 . In this manner, the plurality of light panels 101 can be collapsed, wherein one light panel is folded onto an adjacent light panel. [0049] FIG. 5 is a perspective view illustrating a method of collapsing a lighting device 100 . A lighting device comprising a plurality of light panels 101 can be collapsed according to a roll-up method, which allows a lighting device 100 comprising two or more individual light panels 101 to be collapsed into a roll 151 . [0050] FIG. 6 is a perspective view of a flexible lighting device 200 . A flexible lighting device 200 can comprises a plurality of light emitting elements 103 encased between a flexible base material 201 and a flexible lens material 202 , and can be controlled by an electronic control system 107 . In one embodiment, electrical power can be provided to the flexible lighting device 200 by a power source 105 or an electrical cord 106 . [0051] The light emitting elements 103 can be circular in shape, and can comprise one or more individual light emitting elements, however, in other embodiments the light emitting elements 103 can be any shape that is desired for additional functional or aesthetic requirements. For example, the light emitting elements 103 can be rectangular, triangular, or long thin strips. Light emitting elements 103 can be spaced apart from adjacent light emitting elements 103 such that if light modules are rigid, the entire flexible lighting device maintains flexibility and may be rolled up. Depending on the size of the light emitting elements 103 , a space between adjacent modules can be optimized for maximum lighting. For example, larger more powerful light emitting elements 103 may require larger space between adjacent light emitting elements 103 to prevent the flexible lighting device 200 from becoming a rigid mat of light emitting elements 103 . Further, light emitting elements 103 can be connected to one another electrically by a wire harness 104 . Light emitting elements 103 can be positioned facing different directions to provide multi directional illumination. [0052] In this exemplary embodiment, the flexible base material 201 can comprise one or more materials selected from the group of materials comprising: plastics, polyurethane, vinyl, and rubber. The flexible lens material 202 can comprise one or more materials selected from the group of materials comprising: plastics, polyurethane, vinyl, and rubber. In one embodiment, the flexible base material 201 and the flexible lens material 202 can comprise the same material. However, in other embodiments the flexible base material 201 and the flexible lens materials 202 can be different materials. Further, the flexible lens material 202 can comprise a translucent material or a transparent material, and the flexible base material 201 can comprise a translucent material, a transparent material, a reflective material or an opaque material. [0053] FIG. 7 is a perspective view illustrating a method of mounting a lighting device 100 . A light panel 101 can comprise a plurality of mounting tabs 114 , which can be used to hang or position the lighting device 100 . In one embodiment, the mounting tabs 114 can be manufactured as part of a light panel 101 . However, in other embodiments, the mounting tabs 114 can be separate components which can be attached to the light panel 101 . [0054] FIG. 8 is a perspective view illustrating a method of mounting a lighting device 100 . A light panel 101 can comprise a plurality of mounting magnets 115 , which can be used to hang or position the lighting device 100 in a variety of applications. In one embodiment, the mounting magnets 115 can be manufactured and molded into any one of the material housings, such as, the base material 110 or lens material 111 . In other embodiments the mounting magnets 115 can be connected to the light panel 101 by a press fit friction joint or adhesive bonded to either the base material 110 or lens material 111 .
A collapsible lighting device including a plurality of light panel sections, each light panel section comprising a plurality of light emitting elements, at least one connection element constructed and arranged to connect one or more light panel sections of the plurality of light panel sections to one another, and an electronic control system configured to distribute electrical power to the plurality of light emitting elements.
5
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electroluminescence display device comprising electroluminescence elements and thin film transistors. 2. Description of Prior Art In recent years, electroluminescence (referred to herein after as “EL”) display devices comprising EL elements have gained attention as potential replacements for CRTs and LCDs. Research has been directed to the development of EL display devices using, for example, thin film transistors (referred to hereinafter as “TFT”) as switching elements to drive the EL elements. FIG. 1 is a plan view showing a display pixel of an organic EL display device. FIG. 2A shows a cross-sectional view taken along line A—A of FIG. 1 while FIG. 2B shows a cross-sectional view taken along line B—B of FIG. 1 . As shown in these drawings, a display pixel 20 is formed in a region surrounded by a gate line GL and a data line DL. A first TFT serving as a switching element is disposed near an intersection of those lines. The source of the TFT 1 simultaneously functions as a second capacitor electrode 3 such that, together with a first capacitor electrode 2 , it forms a capacitor 8 . The source is connected to a gate electrode 15 of a second TFT 4 that drives the organic EL element. The source of the second TFT 4 contacts with an anode 6 of the organic EL element, while the drain of the TFT 4 is connected to a power source line (drive line) VL. The first capacitor electrode 2 , which is made of a material such as chromium, overlaps, over a gate insulating film 7 , the second capacitor electrode 3 integral with the source of the first TFT 1 . The first capacitor electrode 2 and the second capacitor electrode 3 together store charges with the gate insulating film 7 being interposed therebetween as a dielectric layer. The storage capacitor 8 serves to retain voltage applied to the gate electrodes 15 of the second TFT 4 . The first TFT 1 , the switching TFT, will now be described. First gate electrodes 11 made of refractory metal such as chromium (Cr) or molybdenum (Mo) are formed on a transparent insulator substrate 10 made of quartz glass, non-alkali glass, or a similar material. As shown in FIG. 1, the first gate electrodes 11 are integrally formed with the gate line GL such that a plurality of these electrodes extend from the gate line GL in the vertical direction in parallel with each other. Referring to FIG. 2A, the first capacitor electrode 2 formed in the same process as that of the first gate electrodes 11 is provided to the right side of the first gate electrodes 11 . This first capacitor electrode 2 , which constitutes the storage capacitor 8 , has an enlarged portion between the first TFT 1 and the second TFT 4 as shown in FIG. 1 and is integral with a storage capacitor line CL extending therefrom in the directions. A first active layer 12 composed of poly-silicon (referred to hereinafter as “p-Si”) film is formed on the gate insulating film 7 . The first active layer 12 is of a so-called LDD (Lightly Doped Drain) structure. Specifically, low-concentration regions are formed on both sides of the gate. Source and drain regions, which are high-concentration regions, are further disposed on the outboard sides of the low-concentration regions. On the first active layer 12 , a stopper insulating film 13 made of Si oxidation film is formed so as to prevent ions from entering the first active layer 12 . An interlayer insulating film 14 formed by sequential lamination of a SiO 2 film, a SiN film, and a SiO 2 film is provided on the entire surface over the gate insulating film 7 , the active layer 12 , and the stopper insulating film 13 . The data line DL which functions as a drain electrode is electrically connected, through a contact hole C 1 formed in the interlayer insulating film 14 , to the drain in the active layer 12 . A planarizing insulating film 18 made, for example, of an insulating organic resin is also formed over the entire surface for planarization. In EL display devices which are driven by an electric current, the EL layers must have a uniform thickness. Otherwise, current concentration may occur in a portion of the layer having thinner thickness. Thus, a significantly high level of planarity is required at least in portions where the EL elements are to be formed, and therefore the above-described planarizing film 18 made of a material having fluidity prior to hardening is employed. The second TFT 4 which drives the organic EL element will be described with reference to FIGS. 1 and 2B. On the insulating substrate 10 , second gate electrodes 15 made of the same material as the first gate electrodes 11 are provided, and a second active layer 16 is further formed on the gate insulating film 7 . Then, a stopper insulating film 17 is formed on the second active layer 16 in a manner similar to the above-mentioned stopper insulating film 13 . Intrinsic or substantially intrinsic channels are formed in the second active layer 16 above the gate electrodes 15 , and source and drain regions are formed on respective sides of these channels by doping p-type impurities, thereby constituting a p-type channel TFT. The above-described interlayer insulating film 14 is provided on the entire surface over the gate insulating film 7 and the second active layer 16 , and the power source line VL is electrically connected, through a contact hole C 2 formed in the interlayer insulating film 14 , to the drain in the active layer 16 . Further, the planarizing film 18 is formed over the entire surface, such that the source is exposed through a contact hole C 3 formed in the planarizing film 18 and the interlayer insulating film 14 . A transparent electrode made of ITO (Indium Tin Oxide) that contacts the source through this contact hole C 3 , namely, the anode 6 of the organic EL element 20 , is formed on the planarizing insulating film 18 . The organic EL element 20 is formed by laminating, in order, the anode 6 , an emissive element layer EM comprising a first hole transport layer 21 , a second hole transport layer 22 , an emissive layer 23 and an electron transport layer 24 , and a cathode 25 made of a magnesium-indium alloy. The cathode 25 is substantially disposed over the entire surface of the organic EL elements. The principle and operation for light emission of the organic EL element is as follows. Holes injected from the anode 6 and electrons injected from the cathode 25 recombine in the emissive layer 23 , to thereby excite organic molecules constituting the emissive layer 23 , thereby generating excitons. Through the process in which these excitons undergo radiation until deactivation, light is emitted from the emissive layer. This light radiates outward through the transparent anode via the transparent insulator substrate and resultant light emission is observed. As shown in FIG. 2B, the cathode 25 which drives the organic EL element is formed on the entire surface over the display pixel region as a common electrode, and is electrically connected to a terminal provided at one end of the transparent substrate 10 . The above-described structure, however, suffers from the following disadvantages. Namely, a DC or AC potential (most commonly a DC potential for an organic EL) is externally applied to the cathode 25 , so that a current flows between the anode 6 and the cathode 25 . Therefore, when the cathode 25 and the lines connected to the cathode 25 have high contact resistance or high line resistance, the bias to be applied to the cathode 25 is lowered, thereby degrading display quality. SUMMARY OF THE INVENTION The present invention was made in light of the above described disadvantages, and aims to prevent voltage drop caused by line resistance when an external power source is connected to a cathode. To achieve the above object, according to one aspect of the present invention, there is provide an electroluminescence display device comprising, on an insulating substrate, a display region including a plurality of electroluminescence elements and a group of terminals disposed at an end portion of said substrate for connecting the device externally, wherein each of said plurality of electroluminescence elements comprises a first electrode and a second electrode, of which an upper layer electrode formed in the upper layer is electrically connected to a plurality of terminals of said group of terminals between the region in which said group of terminals are disposed and said display region. According to another aspect of the present invention, there is provided an electroluminescence display device comprising, on an insulating substrate, a display region including a plurality of electroluminescence elements and a group of terminals disposed at an end portion of said substrate for connecting the device externally, wherein each of said plurality of electroluminescence elements comprises a first electrode and a second electrode, one of said first electrode and said second electrode is at least partially formed as a common electrode for a plurality of electroluminescence elements, and said common electrode is electrically connected to a plurality of terminals of said group of terminals between the region in which said group of terminals are disposed and said display region. According to still another aspect of the present invention, in either of the above-described electroluminescence display devices, a wide line is extended from said upper layer electrode or the common electrode toward said group of terminals; lines are extended from corresponding plurality of terminals of said group of terminals toward the upper layer electrode, said lines being gathered to form a wide line; and said wide line at the terminal side and said wide line at the upper layer electrode side are connected in a wide contact portion. By providing a plurality of terminals (cathode terminals, that is, common electrode terminals), a wide line space corresponding to the number of allotted terminals can be obtained between the plurality of terminals and the display region. Accordingly, a wide line can be formed in this space, which can then be used to reduce the line resistance. In addition, it is also possible to form a wide contact for connecting the cathode, which is an upper layer electrode, and the terminals, thereby further reducing the contact resistance. Accordingly, when the plurality of electroluminescence elements emit light by applying a current to the emissive element layer by the first and second electrodes in the electroluminescence display device of the present invention, it is possible to prevent any drop in the current to be supplied due to line resistance. Therefore, it is possible to provide a display device capable of light emission with high luminance while simultaneously reducing power consumption. According to another aspect of the present invention, there is provided an electroluminescence display device comprising, on an insulating substrate, a display region including a plurality of electroluminescence elements and a group of terminals disposed at an end portion of said substrate for externally connecting the device, wherein each of said plurality of electroluminescence elements comprises a first electrode and a second electrode, of which an upper layer electrode, a cathode, or a common electrode, formed in the upper layer is connected to lines extending from said group of terminals in a contact portion, and, in said contact portion, a contact intermediate layer composed of a conductive oxide is provided between said upper layer electrode and said lines. According to still another aspect of the present invention, in the above-described electroluminescence display device, the contact intermediate layer is composed of the same material as the other electrode among said first and second electrodes, which is, for example, said anode. According to further aspect of the present invention, said lines at the terminal side are composed of a metal material. A metal material such as Al is often used for lines, including, for example, the lines drawn from the terminal side. However, oxide is likely to be generated on the surface of a metal material such as Al. According to the present invention, a contact intermediate layer composed of a conductive oxide is provided between the lines in the contact portion which connects the lines extending from the terminal side and the lines extending from the upper layer electrode, the cathode, or the common electrode. It is therefore possible to prevent the line material from being oxidized in the process of forming the contact. Further, because increase in the resistance can be prevented by oxidation of the contact intermediate layer itself, it is possible to ensure low contact resistance. BRIEF DESCRIPTION OF THE DRAWINGS These and other objects of the invention will be explained in the description below, in connection with the accompanying drawings, in which: FIG. 1 is a plan view illustrating a prior art EL display device; FIG. 2A is a cross-sectional view taken along line A—A of FIG. 1; FIG. 2B is a cross-sectional view taken along line B—B of FIG. 1; FIG. 3A is a conceptual view illustrating the overall structure of an EL display device according to a preferred embodiment of the present invention; FIG. 3B is a cross-sectional view taken along line A—A of FIG. 3A; FIG. 4 is a plan view illustrating a display pixel of an EL display device of the present invention; FIG. 5A is a cross-sectional view taken along line A—A of FIG. 4; FIG. 5B is a cross-sectional view taken along line B—B of FIG. 4; FIG. 6A is a conceptual view illustrating a whole structure of an EL display device according to another preferred embodiment of the present invention; FIG. 6B is a view illustrating a contact CN 2 of FIG. 6 A. FIG. 7A is a cross-sectional view taken along line A—A of FIG. 4 when a top gate type TFT is employed. FIG. 7B is a cross-sectional view taken along line B—B of FIG. 4 when a top gate type TFT is employed. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT To begin description of an EL display device of the present invention, a display pixel formed within a display region 300 enclosed by a dot line in FIG. 3A will be described. FIG. 4 is a plan view illustrating a display pixel of an EL display device. Referring to FIG. 4, regions shaded with dots and enclosed by dotted lines indicate regions formed by a gate material, regions enclosed by solid lines are p-Si layers, while hatched regions by dot lines and enclosed by solid lines indicate portions comprising a transparent electrode. Further, regions shaded with diagonal lines and enclosed by solid lines indicate portions formed by a metal material made principally of Al. FIGS. 5A and 5B are cross sectional views taken along lines A—A and B—B, respectively, of FIG. 4 . In the present example, both of the first and second TFTS 1 and 4 are of bottom-gate type, employ a Si film as the active layer, and include gate electrodes 11 , 15 of the single-gate structure. In FIG. 4, a display pixel is formed in a region surrounded by a gate line GL, a data line (drain line) DL and a power source line (drive line) VL. A first preferred embodiment of the organic EL display device according to the present invention will be described in detail with reference to FIGS. 4, 5 A and 5 B. First, a transparent substrate 10 which is insulating at least in the surface portion is provided. In the present embodiment, a metal cap (can) 200 which serves as a sealing substrate is disposed on the top surface of the substrate 10 so as to seal the EL material and protect the EL element against moisture. The metal cap 200 has a dent in the center portion. Because this metal cap 200 is opacity, light emission of the EL element must be transmitted from the substrate 10 , which, for this reason, is transparent and is composed of a material such as glass or synthetic resin. However, when the cap 200 is transparent and the emitted light can be collected from the cap 200 , the substrate 10 need not be transparent. In the principle plane of the transparent substrate 10 , gate lines GL extend in the row direction along the upper side of one pixel region shown in FIG. 4. A first capacitor electrode 2 which functions as a lower layer electrode of a storage capacitor 8 is further provided, with storage capacitor lines CL extending integrally therefrom substantially in parallel with the gate lines GL for connecting the first capacitor electrodes 2 of adjacent pixels. The lines GL, CL and the electrode 2 are both formed in the same layer and are indicated in the drawings as regions shaded with dots. These lines GL, CL and the electrode 2 are made of a refractory metal such as Cr or Ta because of a p-Si film formed by annealing in the upper layer. In this embodiment, the lines GL, CL and the electrode 2 are formed by spattering Cr of approximately 1000˜2000 Å. In patterning, the sides are formed into a tapered shape considering step coverage. Then, a gate insulating film 7 and an active layer are formed on the entire surface using plasma CVD. First, as the gate insulating film 7 , an Si nitride film of approximately 500 Å and an Si oxide film of approximately 1300 Å are sequentially formed in this order from the bottom, and then an a-Si layer of approximately 500 Å is further laminated thereon. The semiconductor layer is first formed as above an a-Si film, which is then treated with annealing as will be described later to form a p-Si film. The p-Si film is then used for a first active layer 12 , a second active layer 16 and a second capacitor electrode 3 which is an upper layer electrode of the storage capacitor 8 . The a-Si film is subjected to dehydrogenation annealing in a nitride atmosphere at approximately 400° C. and is subsequently poly-crystallized into the p-Si film using an excimer laser. Stopper insulating films 13 and 17 made of an Si oxide film provide a mask during doping process for the first and second active layers 12 and 16 . The stopper insulating film may be replaced with a resist mask, which is removed after ion doping. Namely, P (phosphorus) ions are doped in the source and drain using the first stopper insulating film 13 as a mask to constitute an N-channel type TFT as the first TFT 1 . On the other hand, B (boron) ions are doped in the source and drain using the second stopper insulating film 17 as a mask to constitute a P-channel type TFT as the second TFT 4 . The p-Si film is patterned in a desired shape using photolithography, as shown in FIG. 4 . The p-Si layer serving as the active layer 12 of the first TFT 1 overlaps the data line DL near the intersection of the gate line GL and the data line DL and extends so as to traverse the gate electrode 11 . Further provided is the second capacitor electrode 3 which is integral with this active layer 12 and is formed on the gate insulating film 7 as the upper electrode of the storage capacitor 8 . The second capacitor electrode 3 constitutes a storage capacitor 8 together with a first capacitor electrode 2 . This second capacitor electrode 3 composed of p-si extends toward the vicinity of the second TFT 4 where it is electrically connected with the gate electrode 15 of the second TFT 4 via a connection line formed in the upper layer. The p-Si film serving as the active layer 16 of the second TFT 4 , on the other hand, extends from under the power source line VL across the second gate electrode 15 toward under an anode 6 composed of a transparent electrode. An interlayer insulating film 14 is formed over the p-Si film thus patterned in a desired form so as to cover the film. The interlayer insulating film 14 is of a three-layered structure in which, from the bottom, an Si oxide film of approximately 1000 Å, an Si nitride film of approximately 3000 Å, and an Si oxide film of approximately 1000 Å are sequentially laminated using continuous CVD. However, the interlayer insulating film 14 may comprise at least one layer and the film thickness is not limited to the above-described example. On the interlayer insulating film 14 , the data line DL, the power source line VL, and the connection line 30 are formed, as shown in FIGS. 5A and 5B. In the portions of the interlayer insulating film 14 corresponding to a contact hole C 1 formed through the data line DL to the semiconductor layer 12 of the first TFT 1 , a contact hole C 2 formed through the power source line VL to the semiconductor layer 16 of the second TFT 4 , and a contact hole C 4 between the connection line 30 and the second capacitor electrode 3 , through which the semiconductor layer formed in the lower layer is exposed. In a contact hole C 5 formed between the connection line 30 and the second gate electrode 15 , unlike other contact holes, the gate insulating film 7 as well as the insulating film 14 is formed between the layers and therefore the gate insulating film 7 is also etched to expose a Cr gate electrode 15 . The line VL, DL and 30 have a laminated structure of the lower Mo layer of 1000 Å and the upper Al layer of 7000Å and the upper Mo on the Al. The lower Mo layer is a barrier layer. A planarizing film PLN 1 of approximately 2˜3 μm is further formed over the entire surface of the above-described lines and the interlayer insulating film 14 . This planarizing film PLN 1 , together with a planarizing film PLN 2 which will be described below, is employed for planarization in consideration of the emissive element film EM of the organic EL element to be formed above. Namely, the emissive element film EM containing organic EL material is an organic thin film having a laminated structure which comprises, in the present embodiment, a first hole transport layer 21 , a second hole transport layer 22 , an emissive layer 23 , and an electron transport layer 24 . Alternatively, the emissive element film may comprise one hole transport layer. The organic EL element thus configured employs thin films and is driven by an electrical current. Accordingly, unless the films have an extremely uniform thickness, a significant amount of current flows in thinner film portions, where luminance points with extremely strong light emission are generated. At these luminance points, the organic films are easily degraded, which, in the worst case, results in breakdown. To avoid such breakdown, the entire surface including the anode 6 must be as flat as possible. In this embodiment, acrylic liquid resin, for example, is applied as the planarizing films PLN 1 , PLN 2 . Such liquid resin planarizes the top surface with fluidity before being hardened and preserves the planarized surface after hardening. However, the planarizing films PLN 1 and PLN 2 are not limited to an acrylic resin film. In the present embodiment, it is necessary to connect the anode 6 with the source of the second TFT 4 . Therefore, after forming the planarizing film PLN 1 , a contact hole C 3 is first formed through the planarizing film PLN 1 and the interlayer insulating film 14 . Then, the anode 6 is formed on the planarizing film PNL 1 so as to fill the contact hole 3 , thereby connecting the anode 6 with the source region S of the second active layer 16 exposed at the bottom of the contact hole C 3 . The anode 6 is formed by patterning ITO (Indium Tin Oxide) as shown in FIG. 4, and, over the entire surface over this anode 6 , the planarizing film PLN 2 is formed. The planarizing film PLN 2 is then removed to expose the upper surface of the anode 6 except periphery edge of the anode 6 . On the region of the anode 6 thus exposed by removal of the planarizing film PLN 2 , the organic films which constitute the EL element are formed. Specifically, on the anode 6 , an emissive element layer EM including the first hole transport layer 21 comprising MTDATA(4,4′,4″-tris(3-methylphenylphenylamino)triphenylamine), a second hole transport layer 22 comprising TPD (N,N′-diphenyl-N,N′-di(3-methylphenyl)-1,1′-biphenyl-4,4′-diamine), an emissive layer 23 comprising quinacridon derivatives and Bebq 2 (bis(10-hydroxybenzo[h]quinolinato)beryllium), and an electron transport layer 24 comprising Bebq 2 , and a cathode 25 comprising magnesium-silver(Ag)-indium alloy, Al—Li alloy, or Al/LiF or the like are sequentially laminated. The thickness of the organic films is already described. The cathode 25 employs an Al/LiF alloy of 1000˜2000 Å. While the anode 6 must be patterned for each pixel, the films above the anode 6 may be formed with any one of the following structures: (1) a structure in which all the films from the anode 6 to the cathode 25 are patterned for each pixel; (2) a structure in which, in the above structure, the cathode 25 is formed on substantially all the surface over the display region unpatterned; or (3) a structure in which only the anode 6 is patterned for each pixel as in FIG. 4 and the remaining films above the anode 6 are formed unpatterned. However, the cathode 25 , which need not be patterned, is generally formed unpatterned over the entire surface. Further, because the EL layers deteriorate when exposed to water therefore should be protected against moisture, a metal cap (can) 200 is formed so as to seal the EL layers formed in the display region or to seal all the EL layers as in FIG. 3 A. Accordingly, any film with strong moisture resistance characteristics which will not deteriorate the EL layers, such as a resin film, may be employed to cover the EL layers in place of a cap, or a metal cap 200 may be further provided over such a resin film. The principle and operation for light emission of the organic EL element is as follows. Holes injected from the anode 6 and electrons injected from the cathode 25 recombine in the emissive element layer EM, to thereby excite organic molecules constituting the emissive element layer EM, thereby generating excitons. By the process in which these excitons undergo radiation until deactivation, light is emitted from the emissive layer. This light radiates outward through the transparent anode via the transparent insulator substrate, resulting in light emission. Now, the structure including the peripheral portion of the display region 300 will be described with reference to FIGS. 3A and 3B. Referring to FIG. 3A, the outermost region surrounded by the solid line corresponds to the transparent substrate 10 . The rectangular and innermost region surrounded by a dotted line indicates the display region 300 . The rectangular region outside the display region 300 surrounded by one dot chain line corresponds to an organic film region OR where the emissive element layer EM is formed. The lines extending in the vertical direction within the display region 300 to form a combteeth shape, are the power source lines VL. The rectangular region surrounded by the bold solid line outside the organic film region OR indicates the cathode forming region 25 . Further, the region surrounded by the outermost double bold solid lines and shaded with dots corresponds to a sealing region 250 of the metal cap 200 shown in the bottom figure, while the regions surrounded by dotted lines outside and inside of this sealing region 250 correspond respectively to regions covered with the first and second planarizing films PLN 1 , PLN 2 . Terminals T and lines L are exposed beyond the sealed area by the metal cap 200 . In the region between the cathode forming region 25 and the sealing region 250 , vertical drivers VD connected to the gate line GL are formed along the right and left sides of the display region 300 while a horizontal driver HD connected to the data line DL is formed along the upper side of the display region 300 . These drivers VD, HD are composed of a thin film transistor which is formed simultaneously with formation of a thin film transistor formed in the display region 300 . The right and left vertical drivers are connected with each other via, for example, four lines. Terminals T 1 are power source input terminals for applying a voltage to the power source lines VL, and first lines L 1 extend from the two terminals T 1 , respectively, toward the sealed display region 300 . The two first lines L 1 are connected to a common first wide line portion WD 1 in the sealed region. The first wide line portion WD 1 is connected with a second wide line portion WD 2 which extends in the horizontal direction in the lower region of the figure within the display region 300 . The power source lines VL extend from the second wide line portion WD 2 in the vertical (column) direction within the display region 300 . The first lines L 1 , the first and second wide line portions WD 1 and WD 2 , and the power source lines VL are integrally formed using the same material as the data lines DL. Three cathode terminals T 2 are each electrically connected with one of the corresponding second lines L 2 , which extend toward the display region 300 and are connected, through a third wide line portion WD 3 , to a fourth wide line portion WD 4 which extends from the cathode 25 via a contact hole (CN 1 ). The third wide line portion WD 3 is integrally formed with the lines L 2 , which are combined in this wide line portion WD 3 . Terminals T 3 are each connected, via third lines L 3 , with a corresponding one among the four lines for connecting the vertical drivers VD formed along the right and left sides of the display region 300 . In order to prevent these four lines from crossing the first wide line portion WD 1 , in the portion where these lines are indicated by dot lines, they are formed in the lower layer of the wide line portion WD 1 where the layers same as the gates are formed, using the same material as the gates. Further, terminals T 4 are connected via lines L 4 with the horizontal driver HD. As described above, the cathode 25 is connected to the cathode terminals T 2 via the contact CN 1 (the portion in FIG. 3A indicated with X) formed on the third wide line portion WD 3 integrated with the second lines L 2 . Because the space for one terminal and the line connected thereto is allotted according to the whole layout, the cathode contact CN 1 can be of a large width corresponding to the number of cathode terminals T 2 . Further, the third wide line portion WD 3 to which the second lines L 2 are commonly connected and the fourth wide line portion WD 4 extending from the cathode 25 to the contact CN 1 can also have a width which substantially corresponds to the number of disposed cathode terminals T 2 . By thus enabling the fourth wide line portion WD 4 extending through the cathode contact CN 1 to the cathode 25 and the third wide line portion WD 3 extending through the cathode contact CN 1 to the cathode terminal TN 2 to both be wide, line resistance can be reduced. In addition, the cathode contact CN 1 can also be formed so as to have substantially wide width, lowering contact resistance as well. Although three cathode terminals T 2 are employed in this example, the width of the contact CN 1 can be enlarged to thereby reduce contact resistance when at least two cathode terminals are used. FIG. 3B is a cross-sectional view taken along line A—A of FIG. 3A, which shows the vicinity of the cathode contact CN 1 . In FIG. 3B, from right of the figure, a terminal area corresponding to the region where the cathode terminals T 2 are formed, a line area corresponding to the region where the second lines L 2 are formed, and a contact area where a contact hole is formed, are depicted. The terminal T 2 has a three-layered structure in which the lowermost layer T 2 - a is composed of the same material as the gate line, the middle layer T 2 - b is composed of the same material as the data line DL and the power source line VL, and the uppermost layer T 2 - c is composed of the same material as the anode 6 , namely of ITO which constitutes a transparent electrode. The contact hole CN 1 is formed so as to penetrate the planarizing film PLN 1 . A contact intermediate layer CN 1 a composed of oxide is then provided to fill this hole and thereby contact with the third wide line portion WD 3 which is integral with the lines L 2 exposed at the bottom of the hole. Then, the planarizing film PLN 2 is formed on the entire surface, and a contact hole CN 1 is formed in this planarizing film PLN 2 so as to expose the intermediate layer CN 1 a. The cathode 25 is further formed thereabove. Thus, in the contact area, the line L 2 and the cathode 25 are connected with each other via the intermediate layer CN 1 a. Because the intermediate layer CN 1 a is composed of a conductive oxide, problems with remarkable loss of conductivity due to, for example, oxidation being advanced from the surface region under oxidation atmosphere, will not occur. For example, when heat treatment is performed for hardening the first and second planarizing films PLN 1 and PLN 2 , and a treatment for opening the contact hole is also performed, material such as Al is easily oxidized. However, because the exposed portion in the contact hole formed in the first and second planarizing films PLN 1 and PLN 2 is composed of the conductive oxide film described above, rather than of Al which is easily oxidized, the film will not oxidize. Such conductive oxide materials include, for example, ITO. An experiment was executed employing a conductive film of approximately 8000 Å composed of upper and lower layers of Mo and an intermediate layer of Al, which serves as a line, a cathode composed of Al/LiF alloy of approximately 2000 Å, and an ITO of 850 Å interposed therebetween, and the results showed that the contact resistance was reduced by approximately 10% compared to the case where no ITO was employed. This is because, by employing ITO in the intermediate layer of the contact CN 1 as described above, the resistance of ITO is not changed and a preferable contact is therefore maintained even when the contact is exposed in the oxidization atmosphere. Further, a pad area composed of a gate material similar to the lowermost layer T 2 - a of the terminal T 2 may be provided further below the third wide line portion WD 3 in the contact area. Also, the lowermost layer T 2 - a composed of a gate material in the terminal T 2 may be eliminated. The structure in which contact resistance is further reduced will be described with reference to FIGS. 6A and 6B. In the following, description of components similar to those already described for FIGS. 3A and 3B will not be repeated. This structure differs from that shown in FIGS. 3A and 3B, mainly the fifth line L 5 formed along the outer periphery of the display region 300 or the organic film region OR surrounded by the chain line, and the second contact CN 2 . The fifth lines L 5 are connected, in the second contact CN 2 , with the cathode 25 formed above, and are formed along the three sides of the display region 300 except for the side along which the horizontal driver HD is formed in the example of FIG. 6 A. However, the fifth lines L 5 may be formed so as to surround all sides of the display region 300 . The fifth lines L 5 are integrated with the third wide line portion WD 3 , contact with the cathode 25 at the contact CN 1 as shown by a dot line in FIG. 3B, and extend as the second lines L 2 toward the outside of the sealed region to further contact with the cathode terminals T 2 . The fifth line L 5 , similar to the four lines for connecting the vertical drivers VD, employs a crossover structure at the intersection with the first wide line portion WD 1 . Specifically, this structure is employed in the part of the line 5 indicated in FIG. 6A by a dotted line. This is because the fifth line L 5 , similar to the first wide line portion WD 1 , is made of the same material as the power source line VL simultaneously with the power source line V 1 and therefore cannot cross the first wide lines portion WD 1 . Accordingly, at the intersection, the line L 5 composed of the same material with the power source line VL is connected with the layer formed simultaneously with the gate line using the same material as the gate. At the intersection, the fifth line L 5 is thus disposed in the same layer as the gate, while the first wide line portion WD 1 is disposed above, with the interlayer insulating film 7 , 14 being formed therebetween, such that the line L 5 and the wide line portion WD 1 cross each other without short circuiting. The line L 5 is once again formed of the same material as the power source line VL in a layer above the inter-line insulating film 7 , 14 where the intersection region terminates. The fifth line L 5 and the cathode 25 which serves as the uppermost layer covering the surface beyond the display region 300 are connected with each other in the contact CN 2 . At least one contact CN 2 is formed in the regions TD where the fifth line L 5 and the cathode 25 overlap. In the present embodiment, the contact CN 2 is formed at each of the four corners of the display region 300 as shown in FIG. 6 A. Through these contacts CN 2 , the fifth line L 5 and the cathode 25 are connected with each other. Because the fifth line L 5 are integral with the second line L 2 , the cathode 25 and the cathode terminals T 2 are electrically connected at contacts CN 2 . The structure of the contact CN 2 is shown in FIG. 6B in a cross section. The contact CN 2 is of a three-layered structure ( 80 , 82 , 84 ) similar to the terminal area shown in FIG. 3B, and the cathode 25 is connected on the upper layer (a contact intermediate layer) 80 . As shown in FIG. 6A, the fifth line L 5 ( 82 ) extends along at least three sides of the overlap region TD around the display region 300 , and is interposed between the lowermost layer 84 made of the same material as the gate line GL and the intermediate layer 80 composed of a conductive oxide while contacting with both layers in the contact portion CN 2 . As in the contact CN 1 , the intermediate layer 80 composed of a conductive oxide material is formed between the cathode 25 and the fifth line L 5 in the contact CN 2 . Therefore, it is possible to prevent the fifth line L 5 ( 82 ) composed of the same material with the data line DL and the power source line VL formed below from being oxidized, while simultaneously preventing the contact intermediate layer 80 composed of a conductive oxide material from oxidized, thereby enabling the contact resistance to be reduced. Further, as shown in the multi-layer structure of FIG. 6B, the lower line layer 84 composed of a gate material may be provided under the fifth line L 5 composed of Al which is the same material as the data line DL or the power source line VL. In this case, the whole fifth line L 5 may be of a multi-layer structure together with the lower line layer 84 , and the fifth line L 5 and the line 84 made of the gate material are joined. In FIG. 6B, the conductive material 80 composed of oxide is exposed from the second planarizing film PLN 2 only in the portion of the contact CN 2 . Alternatively, the conductive material may be provided as the upper layer line 80 on the entire region where the fifth lines L 5 are formed therebelow, and then the second planarizing film PLN 2 may be removed to expose the conductive material 80 along the fifth line L 5 , thereby connecting the line L 5 with the cathode via the removed portion. This structure can further reduce the contact resistance. Although the line structure used in the bottom gate type TFT has been described, the present invention is also applicable to a top gate type TFT, as will be described as the second embodiment. A top gate type TFT has a plan view pattern which is substantially the same as that of a bottom gate type TFT shown in FIG. 4 . FIGS. 7A and 7B are cross-sectional views taken along lines A—A and B—B of FIG. 4, respectively, depicting a display pixel when the TFT is of a top gate type structure. In FIGS. 7A and 7B, part corresponding to those in FIGS. 5A and 5B are designated by the same or similar numerals. First, an insulating layer 180 formed by laminating a lower layer, which is an Si nitride film of 500 Å with an upper layer, which is an Si oxide film of 500 Å, is provided on the whole surface of a substrate 10 . This Si nitride film serves as a stopper against impurities eluted from the glass. Then, an active layer 12 of the first TFT 101 ; a lower electrode of a storage capacitor 8 , which is integral with the active layer 12 ; and, at a portion where a second layer 16 of the second TFT 104 is formed; a semiconductor layer (p-Si or a-Si) are formed. Over the entire surface over the semiconductor layer, a gate insulating film 107 is formed. A gate electrode 111 and a gate line GL integral with the gate electrode 111 are then formed on the gate insulating film 107 , and simultaneously an upper layer electrode 102 of a storage capacitor 108 is composed of the same material and in the same layer as the gate electrode 111 . The upper layer 102 of the storage capacitor 108 corresponds to the storage capacitor electrode 2 in FIG. 4 and is integrated with the storage capacitor line CL such that it extends in the row direction. The gate electrode may also be made of a material containing Al as a primary component. Al can be employed in this case because the inter-line insulating film 14 can be formed at a low temperature using plasma CVD or the like. Impurities are doped in the semiconductor layer which functions as the active layer while the pattern of the gate electrode 111 is employed as a mask. Since P-channel and N-channel TFTs must be separately fabricated, while either one of P or N type impurities are doped in the active layer of one of the TFTs, the other TFT is masked-with a resist. (This is similarly performed in the bottom gate type TFTs.) After impurities are doped, the semiconductor layer is patterned, and then the gate insulating film 107 described above is formed. Impurities are not doped in the semiconductor layer constituting a lower layer electrode 103 of the storage capacitor 8 due to the upper layer electrode 102 composed of the same material as the gate electrode. Rather, a voltage equals to or higher than that applied to the first gate electrode 111 is applied to the upper layer electrode 102 to cause a channel to be formed in the semiconductor layer, which then functions as a lower electrode 103 . After the doping process, the interlayer insulating film 14 is formed. Then, the data line DL and the power source line VL are formed, and the first planarizing film PLN 1 is further formed thereon. On this film, a transparent electrode serving as an anode 6 is disposed. The anode 6 and the second TFT 4 may be connected via a source electrode 140 formed in the same layer as the power source line VL, or may be directly connected. Further, after the anode 6 is formed, the second planarizing film PLN 2 is provided so as to planarize the first planarizing film PLN 1 and the anode 6 , with the portion of the second planarizing film PLN 2 corresponding to the anode 6 being removed. The EL element 20 which is similar to that in the foregoing embodiment will not be described again. In the present embodiment, the display device employs a three-layered structure composed of, from bottom, the gate electrodes 111 , 115 , a layer made of the same material as the data line, and a layer made of a transparent electrode material, such that the contacts CN 1 , CN 2 can be of a layered structure identical to that shown in FIGS. 3B and 6B. The lines L 1 ˜L 5 are also similar to those in the foregoing embodiment. Although a p-Si film is used as a semiconductor film in the above-mentioned embodiments, a semiconductor film such as a microcrystal silicon film or an amorphous silicon film may be used. Also, although a single gate type TFT has been described, double gate type TFTs may be employed. Further, although an organic EL display device was described in the foregoing embodiments, the present invention is not limited thereto and is also applicable to general light emission devices and to an inorganic EL display device comprising an emissive layer made of an inorganic material, achieving similar advantages. While the preferred embodiment of the present invention has been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the appended claims.
A wide line portion is drawn from a cathode while another wide line portion is formed by gathered lines extending from cathode terminals. A contact of realtively large size is formed in a region where the two wide line portions overlap each other with an insulating film being interposed therebetween, so as to connect both wide line portions. Further, in this contact, the cathode terminals and the cathode are connected through an intermediate layer composed of a conductive oxide material. Thus, a reduction in the voltage to be applied to the cathode as a result of increased line resistance between the terminals and the cathode can be prevented, thereby preventing deterioration of display quality.
7
FIELD OF THE PRESENT INVENTION This invention relates to a non-woven fabric sheet for alkaline storage battery separators obtained by using conjugate fibers having a specific ethylene based copolymer and a method of manufacturing such battery separators. BACKGROUND OF THE INVENTION It is generally known that alkaline storage battery separators use a non-woven fabric sheet having a polyolefin based fiber. Various kinds of olefin based separators which have chemical resistant properties can undergo severe cell reaction when the temperature of the battery electrolyte is increased to about 80 ° C. In addition, polyolefin based fibers such as polypropylene fiber and polyethylene fiber which are alkali and oxidation resistant have fatal faults in that the polyolefin based fibers have poor affinity with battery electrolyte and are poor at holding the battery electrolyte. In order to solve the above mentioned problems, polyolefin based non-woven fabric sheets which are treated with a surface active agent are disclosed in Japanese unexamined laid open patent applications (Tokkai-sho) No. 147956/1983, 194255/1983 and 39362/1986. A non-woven fabric sheet separator using vinylone is disclosed in Japanese patent applications (Tokko-sho) No. 26942/1981 and a non-woven fabric sheet separator using an ethylene-vinyl alcohol copolymer fiber is disclosed in Japanese unexamined laid open patent applications (Tokkai-sho) No. 34849/1983. A non-woven fabric sheet separator using a sulfonated polyethylene fiber or polypropylene is disclosed in Japanese unexamined laid open patent application (Tokkai-sho) No. 175256/1983, (Tokkai-hei) Nos. 57568/1989, and 132043/1989, and in U.S. Pat. No. 5,100,723 (EPC patent publication No. 316916A2/1989). However, according to the above references, the hydrophilic property of a non-woven fabric sheet separator which is treated with a surface active agent was reduced by the elution or deterioration or decomposition of the surface active agent as a result of repeated charging and discharging for a long period. A non-woven fabric sheet separator using vinylon, or an ethylene-vinyl alcohol copolymer fiber had some problems in that the life of a storage battery was shortened due to deterioration and developed a short-circuit which was caused by extended polymer deterioration by an oxidation reaction which a strong alkaline battery electrolyte. According to the sulfonated storage battery separators mentioned above, however, α-polyolefin was subjected to sulfonation with concentrated sulphuric acid at higher than 100° C. or with highly concentrated fuming sulphuric acid or the like. This means that hydrogen substitution in a tertiary carbon is involved. The efficiency of this reaction was inferior. In addition, the introduction of a desired amount of sulfo groups was difficult and the sulfonated storage battery separators above mentioned posed many problems in the process of manufacturing causing considerable damage of the fiber. Further, according to the above reference, the non-woven fabric sheet separator have high rigidity. Therefore, it is not good workability of the assembly storage battery operation. SUMMARY OF THE INVENTION The present invention is intended to solve many of the above problems. An ethylene copolymer having a specific structure which can introduce a desirable amount of sulfo groups efficiently was used under mild reaction condition. The invention provides storage battery separators using conjugate fibers having a specific sectional form and a method of manufacturing such battery separators. It is another object of the invention to provide a good workability of the assembly storage battery operation. In order to meet the above objective, a non-woven fabric sheet separator for an storage battery separator is provided, comprising a first component of an ethylene based random copolymer having a unit represented by the formula --CH 2 C(SO 3 H)(COOH)--, and a second component of a polyolefin having a melting point no higher than 250° C., wherein at least one of the first and second components has a sectional form divided into more than two parts, with each component having at least one exposed surface. It is preferable in this invention that the non-woven fabric sheet comprises a mixture of 30% or more by weight of a conjugate fiber and a polyolefin fiber. The conjugate fiber preferably has a sectional form of a swelling type (evagination) or a substantially polygon type. The conjugate fiber preferably has a mixing ratio of the first component and second component of 10:90 to 90:10, and has a exposure ratio of the first component and the second component of 95:5 to 50:50. According to the invention, the first component of conjugate fiber preferably comprises ethylene based copolymer resin composed of 0.5 to 25% by weight of an ethylenecarbonic monomer preferably acrylic acid and/or maleic acid, 0 to 24.5% by weight of acrylic acid ester and 99.5 to 75% by weight of ethylene. Said second component preferably comprises a polyolefin having a melting point no higher than 250° C. According to the invention, the second component fiber is preferably polypropylene. According to the invention, the non-woven fabric sheet preferably comprises a mixture of 30% or more by weight of said conjugate fiber and the polyolefin fiber. The first component of the conjugate fibers is preferably a thermal bonding component. The exposure ratio of the first component of the conjugate fiber to the surface of the fiber is preferably 95% to 50%. The conjugate fiber has an enhanced fiber forming property, bonding property, hydrophilic property, card machine web forming property, peel resistant property against mechanical stress, and good workability of the assembly storage battery operation. According to the invention, the first component has 0.4 to 4 mol % sulfo groups. Sulfo-group-added ethylenecarbonic acid that is contained in the first component of the conjugate fibers in the non-woven fabric sheet will not in itself produce a sufficiently hydrophilic fiber, if its content in the first component does not reach 0.4 mol %, and there will be gelation or dissolution of fibers in an alkaline liquid if the sulfo content in the first component exceeds 4 mol %. According to the invention, the method of manufacturing storage battery separators comprises: (A) forming a fiber web composed of 30% or more by weight of conjugate fibers by mixing the conjugate fiber of a thermally bonding type in which the fibers comprise a first component of an ethylene based random copolymer (the first component precursor) composed of 0.5 to 25% by weight of an ethylenecarbonic monomer (preferably 0.5 to 25% by weight acrylic acid and/or maleic acid) 0 to 24.5% by weight of acrylic acid ester and 99.5 to 75% by weight of ethylene said copolymer having a melting point Tm 1 ° C. of 70° C.<Tm 1 <130 ° C., and a second component of a polyolefin having a melting point Tm 2 ° C. of Tm 1 +20° C.<Tm 2 <250 ° C. In addition, either the first component or the second component of the conjugate fiber has a sectional form which is divided into more than two parts with each component having at least one exposed surface. In addition, the conjugate fiber preferably has a mixing ratio of the first component and the second component, 10:90 to 90:10, and an exposure ratio of 95:5 to 50:50; (B) forming a non-woven fabric sheet by passing the fiber web through a heating furnace or at least a pair of flat thermal press rollers, thereby forming a non-woven fabric sheet through thermal bonding of the constituent fibers caused by melting the first component of conjugate fiber; and (C) sulfonating the non-woven fabric sheet, thereby introducing sulfo groups into tertiary carbon atom locations of the ethylene based random copolymer of the first component to which carboxylic groups have been bonded. According to the invention, the second component of the conjugate fiber preferably has a sectional form of a swelling shape (evaluation) or a substantially polygon shape. It is preferable in this invention that the sulfo groups introducing is contacted a non-woven fabric sheet with SO 3 gas. According to the invention, a non-woven fabric sheet separator for a storage battery is obtained by mixing more than 30 wt% of a thermal bonding type of fiber comprising at least two components and the surface of the conjugate fiber has many ethylene based copolymer units containing at least one unit represented by the formula --CH 2 CH(COOH) --, the first component precursor having an excellent fiber bonding property. Thus a desirable bonding type of non-woven fabric sheet can be obtained by changing the mixing ratio of the conjugate fiber and the thermal treatment conditions. The first component precursor is the conjugate fiber copolymer comprising a unit having a carboxyl group. Thus, in comparison with other polyolefin based fibers as the second component, the first component precursor can introduce a desired amount of sulfo groups easily, and can impart a hydrophilic property to the surface of the fiber without deteriorating the fiber. Further, at least one of the first and second components of the conjugate fiber has a split sectional form. The exposure ratio of the first component of the conjugate fiber to the surface of the fiber is preferably 95% to 50% which is sulfonated and its hydrophobic property are improved. Thus, the surface of the conjugate fiber is excellently in hydrophilic and only the surface area of the fiber can be enlarged without increasing the weight ratio of the first component, which is a beneficial property in making an extremely strong conjugate fiber. In addition, the problem concerning bonding between the fibers in the drawing process after the conjugate fiber in melt spinning can be resolved. Further, a problem concerning peeling of the fiber can be resolved as the bonding property of the first component and the second component of the conjugate fiber is extremely strong. In addition, since the battery separator according to the invention is soft to form a non-woven fabric sheet, it is good workability of the assembly storage battery operation. BRIEF DESCRIPTION OF THE DRAWING FIG. 1 shows a typical sectional form of the conjugate fiber which was used in the Example 1 of this invention. FIG. 2 shows a typical sectional form of the conjugate fiber which was used in the Example 2 of this invention. FIG. 3 (a)-(d) show typical sectional forms of the other kinds of conjugate fibers which can be used in this invention. FIG. 4 (a)-(f) show typical sectional forms of the other kinds of conjugate fibers which can be used in the invention. FIG. 5 is a graph representing discharge capacity retention against the number of times of charging and discharging the separators of the Examples. DETAILED DESCRIPTION OF THE INVENTION According to the invention, the sulfonation of a conjugate fiber is carried out steadily and easily by using a first component precursor of the conjugate fiber (e.g., an ethylene copolymer containing a unit represented by the formula --CH 2 --CH(COOH) --) before sulfonation. In addition, various kinds of physical processing and separator properties of the fiber were improved by using the conjugate fiber in which at least one of the first and second components has a specific sectional form of split arrangement. The ethylene-based random copolymer containing the unit represented as --CH 2 --CH(COOH)--is the first component precursor of the sulfonated conjugate fibers of the invention and has a melting point below about 130 ° C., while having a strong self-bonding property. Thus, the conjugate fiber is beneficial as a thermal bonding conjugate fiber. In addition, the conjugate fiber has an enhanced fiber forming property, bonding property, hydrophilic property, card machine web forming property, peel resistant property against mechanical stress, and good workability of the assembly storage battery operation. In order to improve the problems above mentioned, the conjugate fiber according to the invention has a specific sectional form such as shown in FIG. 1 to FIG. 4. FIG. 1 shows a sectional view in which the second component is situated in the center in a substantially quadrangular shape. The first component is situated outside of each side of the quadrangle, in a partially circular shape. Thus, as a whole, FIG. 1 has a circular sectional form. FIG. 2 shows a sectional view in which the second component is situated in the center in a four-leaf shape, and the first component is situated outside of the second component. Thus, as a whole, FIG. 2 has a circular sectional form. FIG. 3 (a) shows a sectional view in which the second component is situated in the center in a four-leaf shape. However, in this case, the second component is not divided into four leaves as in FIG. 2. FIG. 3 (b) shows a sectional view in which the second component is situated in the center as two-leaf swelling shape. The first component is situated outside of the second component. Thus, as a whole, FIG. 3 (b) has a circular sectional form. FIG. 3 (c) shows a sectional view in which the second component is situated in the center in the form of a sandwich. The first component is situated outside of the second component. Thus, as a whole, FIG. 3 (c) has a circular sectional form. FIG. 3 (d) shows a sectional view in which the second component is situated in the center in a substantially octagonal shape. The first component is situated outside of each side of the octagon of the second component in a partially circular form. At least one of the first and second components of each form is exposed to the outside of the fiber. FIGS. 4 (a) to (f) show other types of sectional forms which can be used in the invention. According to the invention, any non-woven fabric sheet can be selected and thermally bonded. For example, a non-woven fabric sheet can be selected from a spun-bond non-woven fabric sheet, a needle punched non-woven fabric sheet, a wet process non-woven fabric sheet, a melt-blow non-woven fabric sheet, etc. The details of the invention are described with concrete examples. It is not to be construed that these examples are limitating, but that they are merely illustrative of the invention. EXAMPLE 1 Conjugate fibers consisting of 4 wt% (1.61 mol%) acrylic acid and 96 wt% (98.39 mol%) ethylene having a melting point at 99° C., as a first component, and polypropylene with a MFR (melt flow value) of 30 g/10 min. (at 230 ° C.), as a second component, was used. The weight ratio of the first component and the second component of the conjugate fiber was 20:80 and the exposure ratio of the first component to the surface of the fiber is 85%. The conjugate fiber consisted of 2d×51 mm having a sectional form as shown in FIG. 1. The fibers obtained were made into webs using a roller card. Then, using a hot air penetration machine at 120° C., the fibers were thermally bonded together and pressed by a pair of calendar rollers heated at 80° C. to obtain a non-woven fabric of 65 g/m 2 having a thickness of 0.20 mm. This non-woven fabric sheet was then dipped and held in 10 wt% fuming sulfuric acid heated to 25° C. for 10 minutes. The sheet was then dipped in dilute sulfuric acid and washed with a great quantity of water. After dipping, the sheet was subjected to a neutralization treatment using diluted aqueous ammonia, then sufficiently washed and dried to obtain a non-woven fabric sheet storage battery separator according to the invention. The non-woven fabric sheet had 0.4 m equivalent sulfo groups. EXAMPLE 2 Conjugate fibers consisting of 2d×51 mm having a sectional form as shown as FIG. 2 were obtained using first and second components as in Example 1. The weight ratio of the first component and the second component of the conjugate fiber was 30:70 and the exposure ratio of the first component to the surface of the fiber was 80%. A web of the blend fibers consisting of 70% by weight of the conjugate fibers, and 30% by weight of regular polypropylene fibers at 1.5d×38 mm, were subjected to thermal treatment and thermal press using a pair of calendar rollers as in Example 1. A non-woven fabric sheet was obtained having a weight of 65 g/m 2 and a thickness of 0.2 mm. This non-woven fabric sheet was then contacted and held in 8 vol. % concentrated SO 3 gas heated to 60 ° C. for 30 seconds in gaseous phase, then washed with a great quantity of water. Then, the sheet was subjected to a neutralization treatment using diluted aqueous ammonia, then sufficiently washed and dried to obtain a non-woven fabric sheet storage battery separator according to the invention. The non-woven fabric sheet had 0.2 m equivalent sulfo groups. EXAMPLE 3 A conjugate fiber of 2d×51 mm and having a sectional as form shown in FIG. 4 (e) was obtained using resins as in Example 1 and Example 2. A fiber web consisting of 50% by weight of the conjugate fibers, and 50% by weight of regular polypropylene fibers of 1.5d×38 mm, was subjected to thermal pressing using a pair of calendar rollers heated to 110° C. A non-woven fabric sheet was obtained having a weight of 65 g/m 2 g and a thickness of 0.20 mm. Then the non-woven fabric sheet was dipped and held in 97 wt% condensed sulfuric acid at 80° C. for 3 minutes. then dipped in diluted sulfuric acid and washed with a great quantity of water. Then the sheet was subjected to a neutralization treatment with aqueous ammonia, then sufficiently washed and dried to obtain a non-woven fabric sheet storage battery separator according to the invention. The non-woven fabric sheet had 0.1 m equivalent sulfo groups. COMPARATIVE EXAMPLE 1 A sheath-to-core conjugate fiber consisting of 2d×51 mm fibers with a sheath-to-core component ratio of 50:50 was obtained using resins as in Example 1. The sheath component constituted the first component, and the core component constituted the second component. The conjugate fiber was obtained by spinning and drawing. Fusion of some part of the conjugate fiber was confirmed. The card web which was made of the conjugate fiber had an inferior opening property and entanglement of some of the conjugate fibers was found. The fiber web was subjected to thermal treatment, a calendar process and fuming sulfuric acid treatment. The web was washed and subjected to a neutralization treatment and dried to obtain the non-woven fabric sheet of the comparative example. COMPARATIVE EXAMPLE 2 A blend fiber web consisting of 70% by weight of core-sheath type conjugate fibers of 2d×51 mm, having polyethylene for the sheath portion and polypropylene for the core portion, and 30% by weight of regular polypropylene fibers of 1.5d×38 mm were processed by using a hot air penetration machine at 140 ° C. Then, the sheath component of the sheath-to-core type conjugate fiber was fused to the polyethylene, and the fibers were thermally bonded. The thickness of the conjugate fiber was controlled by passing through a pair of calendar rollers heated to 105 ° C. A non-woven fabric sheet of 65 g/m 2 having a thickness of 0.20 mm was obtained. Then, the obtained non-woven fabric sheet was subjected to sulfonation in the same way as in Example 2 and then washed with water. Then the sheet was subjected to a neutralization treatment using diluted aqueous ammonia, and sufficiently washed and dried to obtain a non-woven fabric sheet storage battery separator. Various physical property tests were conducted on the storage battery separators obtained in the Examples and Comparative examples. Results are shown in Table 1. TABLE 1______________________________________ Com- Com- para- para- tive tiveTest Item Ex. 1 Ex. 2 Ex. 3 ex. 1 ex. 2______________________________________Weight (g/m.sup.2) 68 68 68 68 65Thickness (mm) 0.20 0.20 0.20 0.20 0.20Water content (wt %) 0.95 0.78 0.93 0.95 0.03Liquid absorption 80 85 75 81 0speed (mm)Liquid retention 318 328 315 320 145percentage (%)Alkaline resistance 0.2 0.2 0.2 0.2 0.2(%)Oxidation resistance 0.1 0.1 0.1 0.1 0.1(%)Mechanical strength 95 98 93 87 99retention percentage(%) after sulfonationSeparator strength 9.5 7.8 7.2 6.3 8.5(kg/20 mm)______________________________________ The test items in Table 1 are explained as follows: (1) Water content: After leaving battery separator under conditions of 20° C. and RH of 65% for 24 hours. (2) Liquid absorption speed: Level of absorption liquid when one end of a battery separator sample 25 mm in width has been dipped and held in caustic potash solution with a specific gravity of 1.30 for 30 minutes. (3) Liquid retention percentage: Liquid absorption percentage after a battery separator having been dipped in caustic potash solution with a specific gravity of 1.30 has been suspended for 10 minutes and drained. (4) Alkali resistance: Weight reduction percentage of battery separator after being dipped and held in caustic potash solution with a specific gravity of 1.30 at 80° C. for 30 days. (5) Oxidation resistance: Weight reduction percentage of battery separator after being dipped and held in blend solution composed of 250 ml of 5 wt% KMnO 4 solution and 50 ml of caustic potash solution with a specific gravity of 1.30 at 50° C. for one hour. (6) Mechanical strength retention percentage after sulfonation: Tensile strength retention percentage of a battery separator before and after sulfonation. (7) Separator strength (kg/20 mm); pull strength of a separator having a width of 20 mm after sulfonation. FIG. 5 shows the results of storage battery performance tests conducted using the non-woven fabric sheet storage battery separators obtained in Examples 1 and 2 and Comparative example 1. FIG. 5 shows a graph of the discharge capacity retention percentage of Ni-Cd storage batteries having a capacity of 1,200 mA hr. The batteries were repeatedly charged and discharged. Charging was at 20° C. with 400 mA for 4 hours, and discharging was at 1 Ω constant resistance over 2 hours. The ordinate in FIG. 5 represents the discharge capacity retention percentage, and the abscissa represents the number of charging/discharging cycles. As can be seen from FIG. 5, the batteries using the storage battery separators according to the invention are subject to less discharge capacity reduction after repeated charging and discharging and are durable in that they can withstand long use owing to their excellent affinity to electrolyte. However, the storage battery using the battery separator of Comparative example 1 is subject to discharge capacity reduction by about 1000 times of repeated charging and discharging, which was caused by strength reduction by sulfonation. In addition, according to the result of surface infrared spectrometry of the battery separator, which was obtained in Example 1, Example 2 and Comparative example 1, measured by the ATR method with an angle of incidence of 45° . Using an infrared spectrophotometer (FTIR-8100 by Shimazu Seisakusho), the peak of absorption of the sulfo group was confirmed at 1200 cm 1 . However, in Comparative example 2, the absorption of the sulfo group was not confirmed. As can be seen from the result above mentioned, the storage battery separator according to the invention exhibits excellent affinity to electrolyte without the aid of any surface active agent and has satisfactory liquid absorption and retention properties. Further, the battery separator according to the invention is also durable with respect to alkali resistance and oxidation resistance, and further it is subject to less mechanical strength reduction after sulfonation. Thus, the separator can sufficiently withstand the repeated charging and discharging over a long period when it is assembled in a storage battery. According to the explanation of the invention, the conjugate fibers is easily formed in card machine web forming and the fiber thermally bonds excellently to a polyolefin based fiber to form a non-woven fabric sheet. The alkaline storage battery separator according to the invention has an excellent hydrophilic property and maintains an excellent affinity to electrolyte for a long period and has satisfactory liquid absorption and retention properties, since the conjugate fiber according to the invention can have sulfo groups easily introduced. Further, the battery separator according to the invention is also durable with respect to alkali resistance and oxidation resistance, and the life of a storage battery can be prolonged remarkably. In addition, since the battery separator according to the invention is soft to form a non-woven fabric sheet, it is good workability of the assembly storage battery operation. Further, this invention has various kinds of effects such as providing a stable and economical non-woven fabric separator having an excellent hydrophilic property and excellent strength by using the conjugate fiber having the specific sectional form. As has been shown, the invention is greatly beneficial to industry. The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.
The invention is to a non-woven fabric sheet for a storage battery separator. The sheet has an excellent property of holding electrolyte by using conjugate fibers having a specific sectional form. The sheet comprises an ethylene copolymer having a specific structure which can introduce a desirable amount of sulfo groups efficiently under mild reaction conditions. Conjugate fibers having a split sectional form include a first component and a second component having a radial arrangement. The conjugate fibers are obtained by forming an ethylene based random copolymer containing a unit represented by a formula --CH 2 CH(COOH)--, with polypropylene. Subsequently, a non-woven fabric sheet of a thermally bonding type is obtained by mixing the conjugate fibers with polypropoylene fibers. Subsequently, a non-woven fabric sheet for a storage battery separator is obtained by sulfonating the non-woven fabric sheet using gas such as SO 3 to form a unit of the formula --CH 2 C(SO 3 H)(COOH)--.
3
This application is a continuation of application Ser. No. 096,295 filed Sept. 9, 1987, now abandoned which is a continuation of Ser. No. 783,408 filed Oct. 28, 1985, now abandoned. BACKGROUND AND PRIOR ART The invention belongs to the field of traffic controls, and more specifically, to the control of road faring vehicle traffic in connection with emergency vehicle traffic. Whenever an emergency vehicle is traveling under conditions of urgency, the problem of passing through busy street intersections represents a dangerous problem to both the emergency vehicle and to the general traffic at or in the vicinity of the intersection. The problem has become especially severe in recent years when many drivers travel in air conditioned cars with their windows rolled up and often with the radio turned on so that they may be unable to hear the siren of an approaching emergency vehicle. Many serious accidents happen each year as a result of collisions between emergency vehicles and other traffic. In heavy city traffic there is still another problem in relation to the travel of emergency vehicles. As an emergency vehicle approaches a busy intersection and some of the drivers respond to the siren and pull to the curb and halt, as required, busy intersections become filled with vehicles standing still and often completely blocking the progress of the emergency vehicle. Many inventors have in the past sought to devise practical solutions to these problems. J. O. D. Shepherd, U.S. Pat. No. 2,355,607 issued August, 1944 discloses a system providing radio transmitters mounted on emergency vehicles that radiate a signal that is detected by direction sensitive receivers at the traffic signals and sets the signals such as to admit the emergency vehicle. F. C. Campana et al, U.S. Pat. No. 3,257,641 issued June, 1966 also discloses a system where a vehicle-mounted radio transmitter sets traffic signals to a special emergency light condition that halts all other traffic. J. C. Lesher, U.S. Pat. No. 3,247,482, issued April, 1966 discloses a system where an emergency vehicle-mounted radio transmitter broadcasts simultaneously two subcarrier signals which prevent interference of two vehicles simultaneously attempting to control the traffic lights. Other inventors have disclosed systems that employ sonic or light microwave radio signals in order to control the traffic lights. H. G. Malach, U.S. Pat. No. 3,881,169, issued April, 1975 discloses a system where each intersection has sonic receivers tuned to certain sound frequencies transmitted by an approaching emergency vehicle, so as to direct the traffic lights to guide the vehicle through the intersection. L. L. Rose, U.S. Pat. No. 4,016,532 issued April, 1977 discloses a system in which an emergency vehicle mounted transmitter sends a coded signal to a receiver at the intersection where it causes the traffic signal at the intersection to turn to steady red in all directions. E. Elmasian, U.S. Pat. No. 4,135,144, issued January, 1979 discloses a system in which a radio transmitter mounted in the emergency vehicle causes a receiver at the signal to initiate a light signal sequence that causes the signal to first send flashing red in all directions before turning steady red in all directions. It appears that none of the systems of the prior art have completely solved the problem of coordinating and controlling traffic so as to accommodate an emergency vehicle in transit since none have gained wide acceptance. The main problems, it has been found, reside in the fact that city intersections are often very complex in their physical layout and often several intersections are mutually interacting as heavy traffic flows from one traffic direction to another through such inter-related busy intersections. Additionally, the pattern of traffic flow often changes during the day, such that morning rush hour traffic, for example is different from evening hour rush traffic. The present invention overcomes these problems by providing a two-way interactive encoded communications link between signal controls at an intersection and emergency vehicles, wherein vehicle-mounted communications apparatus transmits, from an approaching emergency vehicle, a digitally encoded message to communications and control apparatus associated with a single traffic intersection or with complicated groups of intersections, that transmits to the control apparatus the identity of the vehicle followed by the desired route through the intersection. The control apparatus at the intersection, in response, inserts the request into an electronic memory bank, residing at the control apparatus, or associated therewith, which in turn provides one of a number of preselected optimal patterns for that intersection, so that the traffic control quickly may clear all traffic lanes to be used by the emergency vehicle instead of blocking them with stalled traffic. The traffic control additionally returns a confirmation code to the emergency vehicle that tells the driver that his request has been received and that he can safely proceed through the intersection. OBJECTIVES It is a primary object of the invention to provide an emergency vehicle traffic control system that uses two-way communication links between emergency vehicles and traffic control apparatus at intersections such that encoded signals from the vehicle informs the control apparatus of the desired route through the intersection, and wherein preselected optimal traffic signal patterns are stored in a memory bank to provide the best possible path for an emergency vehicle through that intersection. It is another important object to provide an emergency vehicle traffic control system that returns a response to the driver that confirms that his request has been received and is being executed by the signal control apparatus. It is still another important object to provide an emergency vehicle traffic control system that is adaptable to changing traffic conditions such as morning and evening rush hour traffic. It is still another important object to provide an emergency vehicle traffic control system that insures against interference between several vehicles operating within the same area at the same time. It is still another object to provide an emergency vehicle traffic control system that can use the two-way radio equipment already installed in the vehicle for the traffic light control. It is still another object to provide an emergency vehicle traffic control system that allows human intervention under unusual circumstances. Still other objectives and advantages will become clear in the course of the following detailed description with appended figures and claims. BRIEF DESCRIPTION OF THE FIGURES FIG. 1a is a diagrammatic "birds-eye" view of an intersection with local emergency traffic control, with an approaching emergency vehicle and the communication links between them. FIG. 1b is a traffic light; FIG. 1c is an embodiment having central control, from a central control station, of the traffic light. FIG. 2 is a diagrammatic "birds-eye" view of a complex intersection with several traffic signals and traffic patterns and linked traffic controls; FIG. 3 is a diagram of a digitally encoded message format used with the invention; FIG. 4 is a diagrammatic view of an emergency vehicle control console as used with the invention showing the major function blocks and their interconnections; and FIG. 6 is a flow-chart diagram of the steps performed by the vehicle and the intersection control apparatus in the execution of a request for transit. FIG. 7 is a diagrammatic layout of the program modules of the control program. DESCRIPTION In the following, a number of preferred embodiments of the invention have been described in detail in relation to the appended drawings. It is to be understood that the invention is capable of other embodiments and is not limited in its application to the details of the particular arrangements shown. The terminology used therein is for the purpose of description and not of limitation. Wherever gender is used, the male gender is used to represent both genders. The term "driver" is used to represent the person or persons in the vehicle operating the vehicle and the traffic control apparatus. FIG. 1a is a "birds-eye" view of a simple intersection consisting of four branches at generally right angles to one another. The branches are designated A, B, C, and D in clockwise direction with branch A pointing North. That convention is used throughout this specification to designate branches to intersections. A traffic signal 2 is suspended above the center of the intersection as is often used in relatively simple cases such as this. A signal control 62, located near the intersection, comprises the apparatus used in connection with the operation of the traffic signal, such as electrical relays with contacts to control the lights, power connections to the main ac-power source, and sequencing apparatus that controls the successive phases of traffic lights. The control also includes the traffic light emergency control apparatus in accordance with the present invention FIG. 1b shows a conventional simple four-sided traffic signal as is commonly used. Each of its four sides has sectors consisting of a red light 18 at the top signalling approaching traffic to stop when facing the red light, a yellow signal 19 in the middle, warning that red is coming next and a green light 21 at the bottom signalling approaching traffic facing the green light permission to proceed. A fourth section 22 at the bottom showing a green arrow is at times used to indicate that left turn or other special conditions are permitted. At some locations multiple signals are located over divided traffic lanes to indicate different turn modes for the different lanes of traffic. There is a great variety in the different ways traffic signals are displayed in different localities, depending on local preferences and policies. It is not necessary to describe these differences in more detail, since the invention is not directed to modes in which the signals are deployed per se, but to the methods used to select and deploy the modes that are preferred in directing emergency vehicles through busy intersections. In FIG. 1a, as the emergency vehicle 1 approaches the intersection from the South on branch C, the driver has turned on his traffic control console 40 shown in FIG. 4 by operating its on-off switch 43 and the "power-on" light 44 indicates power is on. In accordance with the invention each vehicle authorized to operate in the area or jurisdiction of the particular intersection has a unique identity number, which may typically be a three digit number which has been dialed into the three dials generally at 45, consisting of the hundreds digit H, tens digit T and units digit U. These dials may, if merited, be placed under a locked cover and inaccessible to the operating personnel. An alpha-numeric keyboard 42 is used to first key in the identity number or designation code of the intersection being approached together with the branch of ingress to the intersection and the branch of egress requested. It is assumed that the driver has in his possession a chart that shows the identity number or code of the intersections in his area of jurisdiction or has memorized these designations. It should be noted that all the designations could be allocated mnemonic codes as they are now widely used in data systems in order to facilitate the use of the system. The details of coding is, however, immaterial to the inventive concept. As a result, the vehicle control apparatus 47 in FIG. 5 records the above information from the keyboard 42 and stores it in digital code in the data assembler 51. The data assembler prepares a small "packet" or record of information consisting of the characters keyed in and assembles them in a selected sequence so that it can be transmitted serially as a string of characters from the vehicle. The codes used for character transmission is immaterial; the most generally used code is the so-called ASCII code which is described in textbooks on data transmission such as Computer Organization and Programming by William Gear, published by McGraw Hill Library of Congress Catalog No. ISBN 0-07-023076-5 and Digital Systems: Hardware Organization and Design by Frederick J. Hill et al published by John Wiley & Sons, Library of Congress No. ISBN 0-471-39605-2. FIG. 3 shows the format of this information packet consisting of eleven numbered boxes, 1-11. Starting from right to left, box No. 11 represents the departing branch. Assuming that the driver intends to leave at branch D after having made a left hand turn from C, it would contain a "D" in box 11 and a "C" in box 10. Assuming the intersection has identity number 6789, these numerals would be stored in boxes No. 6 through 9. The vehicle identity number would be stored in boxes Nos. 3, 4 and 5. After the characters are assembled in the data assembler 51, a so-called check-sum may be computed by the data assembler. The check-sum is typically the number of "ones" (1's) in the assembled character string contained in the spaces 3 through 11 as they are converted to ASCII code. In the ASCII code format each character consists of an eight bit binary number, which is, again, a string of eight ones or zeroes (1's or 0's). After the character string has been assembled in the format shown in FIG. 3, it is sent to a modulator 53 which modulates a tone frequency that is frequency keyed in two discrete frequencies to produce the ones and zeroes in accordance with industry standards. The modulator is part of a so-called modem which is typically a modulator-demodulator (MODEM) combined into one piece of hardware, with the demodulator 52. The modulator 53 will, when the data assembler 51 is ready, turn on the transmitter 56 which is a radio frequency generator producing a radio carrier in one of the frequency bands allocated for applications of this nature by the Federal Communications Commission (FCC). The transmitter may now be frequency-shift keyed by the modulator and transmits the character string consisting of the 11 characters of FIG. 3 preferably in the numbered sequence. Before transmitting its carrier, however, it is advantageous that the modulator waits until it has checked to see if the radio frequency used is available; in other words, if no other vehicle or traffic signal is currently using the same assigned radio frequency. This function is performed by the demodulator 52 which receives the radio carrier signal from the receiver 54, if the frequency is in use. It should be understood that preferably the invention uses the same frequency for transmissions from vehicle to signal and vice versa. Assuming the frequency is available, at that moment the transmitter will turn on the carrier frequency which could, typically, be in the 180 megaherz range. The transmitter will be modulated in rapid succession by the one's and zero's of the character string of FIG. 3, which with 11 characters each with 8 bits represent 88 bits. The transmitter will typically operate in the frequency modulation mode so that the frequency modulated audio signal from the modulator operates to frequency-shift modulate the radio carrier produced by the transmitter. The transmitter is connected to an antenna 57 mounted on the vehicle, and transmits the character string to the distant antenna 61 located at the intersection signal control 62, where it is received by the receiver 64. As soon as the message is transmitted, the transmitter at the vehicle turns off its carrier. The transmission may typically take a small fraction of a second at a carrier frequency above 30 megaherz. The signal control apparatus at the intersection having now received the request from the emergency vehicle with the information containing the identity of the vehicle and the driver's path of transit through intersection proceeds to execute the request. The dashed line box 62 of FIG. 5 shows the major function blocks of the signal control apparatus. The receiver 64, already mentioned, sends the received character string of 88 characters through the demodulator part (DEM) 74 of a modem 74, 73, also containing the modulator 73 (MOD). The modem here performs a function that is similar to that of the modem 52, 53 in the vehicle control 47. The digital, binary character string produced by the demodulator is sent to a bus interface (BUS IF) 75 which communicates with a digital bus 80 which is, in turn, a part of a micro-processor control system consisting of the central processing unit (CPU) 69, memory section consisting the read-only memory (ROM) 66, the random access memory (RAM) 67 and a maintenance test unit (MA-TE) 68 and the electronically alterable ROM, the EROM 70. Microprocessor systems contain a microprocessor unit (CPU) that is connected with memory sections. The memory sections contain all control programs in binary coded numbers. Each memory section consists of memory cells, each of which may exist in two states, namely as a "one" (1) or a "zero" (0), also designated "on" or "off", respectively. The ROM memory 66 contains, in stored digitally encoded form, the control programs which constitute the control functions for the control system. The RAM memory 67 contains transitory information which the CPU requires in order to perform its operations. The control programs in memory are subdivided into smaller sub-sections or modules, each having discrete defined functions within the entire control system. FIG. 7 show the more significant sub-sections of the control program and is described in greater detail below. The control programs consist of sequentially numbered listings of digitally encoded instructions that are stored in the memory. The instruction format and encoding is part of the instruction set which is again a part of the structure of the microprocessor, as originally established by the designer of the microcomputer. The control programs, acting through the hardware of the microprocessor, are capable of operating on and monitoring other sections of hardware which are part of the entire control system. The ROM 66 contains the control programs that are rarely changed. The RAM 67 contains program information that is transitory and changes frequently. The maintenance-test unit 68 MA-TE contains programs and hardware that monitor the operation of the system and produces an alarm that may be transmitted to a remote, attended location if equipment malfunctions are detected. The lights in the signal 2 are operated by a regular signal control 71 which performs the continuous, periodic sequencing of the lights during normal traffic conditions. It may contain conventional hard-wired logic components, as in most older systems or it may be controlled by the CPU 69 over the bus 80 as in newer systems. Whichever method of operation is used for this function is immaterial in view of the invention. An emergency signal control 72 takes over the light control in case an emergency vehicle request is being executed by the signal control, and is, for this purpose, connected to the CPU bus 80. In this case, the operation of the regular signal control 71 is pre-empted. The operation of the signal control 62 is shown in functional steps in the flow chart of FIG. 6, which traces the steps in the execution of an emergency request. The symbols of the flow chart are conventional and standard and are described in reference books on control systems, as in aforesaid referenced sources. The first step 76 is the request for an emergency transit through the intersection. The next step is the decision point 77. If the signal control 62 is engaged in the execution of a request from another emergency vehicle a "WAIT" message 96 will be sent back to the vehicle through the NO branch at 77. If the signal control is ready to execute the request, the next step 78 is to interpret the information in the received request message. As part of the interpretation, the validity of the request message is checked including the validity of the vehicle identity number. Next the time of the day is noted in step 79 and based on this, a predetermined, stored emergency traffic pattern is selected from a library of such patterns stored in ROM 66 or EROM 70 in step 81. The emergency traffic pattern places the system in the emergency signal control mode in step 82 which affords the emergency vehicle safe transit through the intersection. After completing the transit, the emergency vehicle driver will normally execute a "Transit Complete" message as in step 83, which will restore operation to the regular mode in step 84. He might, however, happen to neglect to issue that message and a timing function 86 that was start at the beginning of the request starts a timer in 87. If the "Transit Complete" message is received, the timer 87 is reset in 95, but if not, the "Timer On" 87 goes to the decision point 91. If the time-out period has elapsed, the "Yes" branch restores normal operation in 84, but if time-out has not elapsed, the "No" branch continues the timer. At the start of the execution of the emergency signal control mode in step 82, the received message is transmitted back to the emergency vehicle control in step 89. The vehicle control 47 compares the returned message with the original message in step 92 that tells the vehicle control 47 that the signal had received the message as transmitted and started the execution of the request. The comparison is done at the vehicle in step 93, which is a decision point. If the comparison affirms the message, the "Yes" branch from 93 goes to step 94, which produces a "Proceed" message in the vehicle that tells the driver that he may proceed safely. In case step 93 is negative indicating that the message returned was not the same as transmitted, the "No" branch from step 93 produces a "Repeat" message 97 at the vehicle which is displayed at the control console and tells the driver that something is amiss. He may then repeat the request or take different action at his discretion. The vehicle control 47 as shown in block diagram in FIG. 5 contains a control logic unit 45 which provides the internal vehicle control logic functions that correspond to those performed by the control processor in the signal control 62, except it will have a different control program and will typically have less complexity. The basic operational steps of the control logic 45 were included in the flow chart of FIG. 6. It follows that several additional functions may be included in the construction, such as self tests, diagnostic tests and others which are conventional and are typically included in such systems and which are well known to those skilled in the art of designing control logic systems. In FIG. 4, the display 41 and keyboard 42 are parts of the vehicle console 40 shown in FIG. 4. The display 41 is capable of displaying messages such as "Proceed" or "Wait" or "Repeat" to the driver as appropriate or maintenance and systems status messages to inform the driver of the system status. The keyboard 42 is typically an alpha-numerical board as used on a conventional type writer or it may be abbreviated to include only the keys required to send the special messages labeled thereon and the numeric keys. Such an abbreviated keyboard will have less capability, but may be less expensive and occupy less space in the vehicle cab. The control programs which are stored in the central processor's memory sections are organized in smaller sections typically called modules. The major modules of the control program are shown in FIG. 7. A main program 46 ties together and coordinates the operation of the individual modules. The Clock Calendar 47a which produces time of day and the date, the Interpret Request module 48 receives the request information in the format shown in FIG. 3, organizes and validates it, if applicable, and transmits it to the Emergency Signal Patterns module 52a which produces a preselected signal pattern which it transmits to the Signal Controller module 49, which transmits the control commands to the Emergency Signal Control block 72 in FIG. 5. A test routine module 51 continuously monitors the operation of the entire system and indicates any malfunctions it detects and decides, if applicable, what action to take, in order to correct the malfunction. In a second embodiment of the invention, shown in FIG. 1c, the vehicle 1 does not communicate directly with the signal control 62 as described above but with a central control 3 which may be located at some central location from where it may serve a plurality of traffic signals. In the latter case, the vehicle radio equipment communicates via a two-way link 13, 14 with two-way radio equipment 4, 8 connected to an antenna 6 at the central location 3. A wire communication link 9 is then provided to connect the central control 3 with the signal control 62, instead of the radio link 16, 17 used in the first embodiment. A system structured in this way has the advantages that the vehicle's normal two-way voice communications system, which is normally more powerful and farther reaching than a small dedicated separate two-way radio provided for signal control only, and is already normally provided in most emergency vehicles for general voice communications. Furthermore, the maintenance of a single central radio system is often more desirable and reliable than the maintenance of multiple, distributed small units, and a wire link such as provided in this embodiment is very reliable and economical and may readily be used also to transmit equipment alarms and malfunctions back to a central, attended location. It has the additional advantage that human intervention may be added to the centrally located system by the addition of an operator console 13 connected to the centrally located control 3 via a link 12 in an adjacent or another remote location 14. The human operator may be equipped to override the decisions made by the automatic equipment. He may also be able to control the signals in response to verbal requests from an emergency vehicle in cases in which the automatic vehicle control is not functional or not installed. In the second embodiment different modes of operation may be provided relating to the interactions between the central control unit 3 and the signal control 62. In one of the preferred modes, the central control 3 receives the character string and transmits the confirmation over the radio link (13, 14), as did the radio receiver and transmitter in the signal control 62 in the first preferred embodiment. In the second embodiment that information is then transmitted via the wire link 9, to and from the signal control 62 which still has residing with it, as in the first embodiment, the function blocks pertaining to central processor, memories, signal controls, memories, modem and bus interface 75, as described under the first embodiment. In the case of the added human intervention with a console 13, the human operator can receive verbally the request for transit through an intersection from an emergency vehicle and from his console, that may be similar to the vehicle console of FIG. 4, activate the emergency signal control mode. It follows, that with the second embodiment, if human intervention is provided a fleet of emergency vehicles may contain vehicles that do not have a vehicle control 47 installed. In this way, an economical gradual transition can be made from a manual system to a system that is fully automatic. It follows that the present invention may be embodied such that smaller groupings of street intersections that share a centrally located control may be created by a combination of the elements of the first and of the second embodiment. Such an arrangement may be advantageous in large complex intersections consisting of several interacting smaller junctions, as shown in diagrammatic form in FIG. 2, where two intersections, the main intersection with branches A, B, C, D, E and a smaller intersection with branches F, G, H and I to the South. The main intersection has a main signal control 62-1 with an attached second control 62-2, both being served by a central control 3-1 which contains the radio equipment. Two wire links 9-1 and 9-2 serve the two signal controls 62-1 and 62-2 respectively. OTHER EMBODIMENTS AND CAPABILITIES In the foregoing specification two preferred embodiments of the invention have been described. As explained, the preferred mode of operation employs an interactive method of two-way radio transmissions between a traffic light control and an emergency vehicle where all units, vehicular as well as stationary transmit short bursts of digitally encoded radio messages, all on the same frequency. The communications protocol provides that any unit, before it transmits a message insures that the frequency is available. If two units should transmit at the same time, or there is other interference, a check-sum embedded in the message informs the receiving unit that the message transmitted is incomplete and confirmation is not returned. If confirmation is not returned, the first transmitting unit, after a random delay, may repeat the message, and the probability is very small that a second attempt will fail, or that a third should fail and so forth, after repeated attempts. The traffic signal light control of intersections according to the invention affords a high degree of protection against interference of the light control from simultaneous operation of several emergency vehicles, in the same general area because the first vehicle seizing control of the light delivers to the signal control the unique identity of that vehicle where it is stored in its electronic memory, for the duration of the execution of the vehicle's transit through the intersection. In the second embodiment, employing central control of the signals, both the vehicle identity and the intersection identity is known to the control apparatus and nearly simultaneous requests can be separate by the control apparatus. The traffic signal control of the invention has the significant advantage that no special light signals are required which could confuse drivers of the general traffic or out-of-town drivers. In the second embodiment with human intervention it is possible to accommodate special traffic conditions that emergency in unusual situations which could not have been predicted, such as large fires, civil disturbances and catastrophies and so forth. The signal light control, according to the invention, affords the capability of adding encryption of the encoding of the character strings used in the system for two-way communications. Such encryption eliminates or reduces the dangers from malicious interference with the system. Encrypting algorithms are now readily available, which provide a high degree of integrity of the transmissions. Encryption algorithms would in this case be added to the control programs in both the vehicle control and the signal control. In FIG. 7 an encryption algorithm module 55 is shown, under the main program. The signal light control system according to the invention affords a simple means for adding rank or priority to different emergency vehicles by adding priority ranking to the vehicle identity code. Such a ranking table could be built into the control program at the signal control. In FIG. 7 a priority ranking module 50 is shown which inserts the vehicle identity code into the ranking table and allocates competing requests for transit in accordance with the priority ranking of the vehicle. The signal light control, according to the invention affords a simple method of recording the time and vehicle identity of each emergency vehicle transit through the intersection by the expedient of not erasing such information after transit is completed but by means of storing it, either in a transaction memory module provided for the purpose, as shown as transaction record at 60 in FIG. 7. This memory module may then, later, be interrogated by the attachment of a paper printer or other display device. Such records may be of value in later evaluation of the selected efficiency of the selected control patterns stored in the selected signal pattern module 52 or may be valuable in the settling of the question of when transit took place. The memory module provided for storing past operations is shown as the Transaction Record 60 in FIG. 7.
A traffic light control system which includes two-way communications between a moving emergency vehicle approaching a busy intersection with one or more traffic lights, arranged so that the traffic light control apparatus has stored therein preset patterns of response that temporarily preempt the usual operation of the traffic light and instead provides the most effective method of routing the vehicle through the intersection while redirecting general traffic. As part of the invention, the traffic light control mechanism returns acknowledgement of receipt of instructions to the emergency vehicle. The stored preset traffic patterns may in one embodiment be responsive to human intervention from a dispatching center or to time-of-day conditions. The stored traffic patterns in still another embodiment may be arranged to include a plurality of coordinated intersections. In still another embodiment, the traffic light control apparatus may be operated under control of data or voice transmitted from the emergency vehicle's regular two-way voice communications system to a central, attended control station.
6
FIELD OF THE INVENTION [0001] The present invention relates to the field of chemotherapeutics, particularly to their formulation as of oral pharmaceutical compositions containing bioenhancers for increasing bioefficacy of anti-infectives and thereby requiring lower doses and/or decreased frequency of dosing of such anti-infectives while maintaining the therapeutic efficacy of standard doses of such drugs. BACKGROUND OF THE INVENTION [0002] A variety of human ailments owe their origin to pathogenic microorgnisms, which include bacteria, virus and fungi. The presence of such pathogenic microorgnisms lead to septicaemia, serious infections of upper and lower respiratory tract, CNS, meningitis, intra-abdominal including peritoneum, genito-urinary tract, skin, and soft tissue, and variety of other infections like systemic mycosis, candidiasis including infections caused by dermatophytes. During the last 100 years, significant progress has been made to combat the diseases caused by such a large family of microbes with innumerable therapeutic agents of diverse chemical and biological nature that have become available as a short and long-term cure. Such antimicrobials include aminoglycosides, penicillins, cephalosporins, macrolides, glycopeptides, fluoroquinolones, tetracyclins, first and second line anti-TB drugs, antileprosy, antivirals, polyene, txiazole, and imidazole anti-fungals, combinations like pyrimidine derivatives and trimethoprim and sulphamethoxizole. [0003] While such agents are effective against pathogenic bacteria and fungi and therefore usefiul in the treatment of disease conditions associated with the presence of such pathogens, there is increasing evidence that use of such agents has certain limitations and led to clinical concern. There are several such factors responsible for such a concern: (a) certain strains of bacteria and fungi become increasingly resistant to one or more of the known anti-infectives and therefore the usual or standard therapeutic doses lead to less beneficial effect, (b) higher doses that are required to combat this cause undesirable side effects and toxicity, and (c) high-cost of treatment and patient-non-compliance. The emergence of drug-resistant pathogenic organisms has also been attributed to uncontrolled antibiotic overuse and under use and even under dosing, irrational frequency of administration. The prolonged and high dose therapy is also a matter of serious concern particularly in pregnant women, geriatrics and children. [0004] While an approach embodying rational use of antibiotics use may help slow the problem of microbial drug resistance, new antimicrobial agents must be discovered to combat those strains that are now resistant to most, if not all, currently available antibiotics. As such, there is a continued interest in the identification of novel antimicrobial agents, which can be used to further supplement the medical practitioner's armamentarium against pathogenic microorganisms [0005] In another approach, two anti-infectives are combined in such a way that the combination produces synergy i.e. one of the anti-infective acts as the potentiator of the other antiinfective. The example of such combination is Trimethoprim-sulfamethoxazole also known as co-trimoxazole or TMP-SMX, which was introduced in 1968 as a broad-spectrum antimicrobial agent. Trimethoprim was specially developed as a potentiator of sulphonamide to act synergistically against bacteria and delay the development of bacterial resistance. The 1:5 ratio of trimethoprim to sulfamethoxazole achieves an approximate 1:20 ratio of peak serum concentrations which is the optimal synergistic ratio of serum concentrations against most susceptible bacteria (Gutman L T, Pediatr Infect Dis 1984; 3 :349-57, Olin B R, Facts and Comparisons, Inc. 1998; 408b-409d, Cockerill F R, Edson R S, Mayo Clin Proc 1991; 66:1260-9) [0006] The combination can also be between one antiinfective agent and another chemical agent which by itself is not antiinfective in nature but when combined with the antiinfective, enhances the effectiveness of this antiinfective. The example of such combination is Amoxicillin+Clavulanic acid, more commonly known as Augmentin. Amoxicillin is an antibiotic of the penicillin type. It is effective against different bacteria such as H. influenzae, N. gonorrhea, E. coli, Pneumococci, Streptococci, and certain strains of Staphylococci. Chemically, it is closely related to penicillin and ampicillin. Addition of clavulanic acid to amoxicillin in Augmentin enhances the effectiveness of this antibiotic against many other bacteria that are ordinarily resistant to amoxicillin. Clavulanic acid is produced by the fermentation of Streptomyces clavuligerus . It is a β-lactam structurally related to the penicillins and possesses the ability to inactivate a wide variety of β-lactamases by blocking the active sites of these enzymes. Clavulanic acid is particularly active against the clinically important plasimd mediated β-lactamases frequently responsible for transferred drug resistance to penicillins and cephalosporins. [0007] One of the most notable features that has been associated with the traditional Indian medicine and amply described in Ayurveda is the use of compositions which offer additive, synergistic and potentiating effect of one medicament when used in combination with the other. In Ayurveda there are several natural products, which have been used as an essential ingredient of many formulations used against wide range of diseases. The most prominent of these being ‘Trikatu’ comprising black pepper, long pepper and dry ginger. Detailed and systematic studies have shown that one of the active ingredients of peppers i.e., piperine is a potent bioavailability and/or bioeffacicay enhancer of several drugs and nutrients. The process of obtaining piperie and piperine cont formulations including anti-TB antibiotics with enhanced bioavailability/bioefficacy at lower doses of active drugs has been disclosed in earlier patents (IP 172684,; IP 172690,; IP 176433; U.S. Pat. No. 5,439,891). OBJECTS OF THE INVENTION [0008] The main object of the invention is to provide a oral pharmaceutical compositions containing bioenhancers for increasing bioefficacy of anti-infectives and thereby requiring lower doses and/or decreased frequency of dosing of such anti-infectives while maintaining the therapeutic efficacy of standard doses of such drugs. SUMMARY OF THE INVENTION [0009] The present invention deals with one such combinations, where piperine and other bioenhancers are used as potentiators when combined with various anti-infective agents in vitro using bacteria, viruses and yeast and in vivo using mice and guinea pig infection models. The present invention is aimed to overcome or avoid problems faced in the prior art. The use of products of the present invention offer a low dose regimen that produces enhanced therapeutic action comparable to that of standard dose alone. [0010] Accordingly, the present invention provides a composition useful for enhanced therapeutic effect at reduced doses of the anti infectives against infection caused bya microorganism comprising a mixture of an anti-infective agent and a bioenhancer selected from piperine of formula 1 and 3′,5-Dihydroxy flavone 7-O-β-D-galacturonide-4′-O-β-D-glucopyranoside of formula 2 or a mixture thereof. [0011] In one embodiment of the invention, the anti infective agent is selected from the group consisting of penicillins including semi synthetic, cephalosporins, aminoglycosides, glycopeptides, fluroquinolones, macrolides, tetracyclines, first and second line anti-TB drugs, antileprosy drugs, oxazolidelones, antifungal agents, antiviral agents and pyrimidine derivatives—sulphonamides combination. [0012] In a further embodiment of the invention, the anti-fungal agent is selected from the group consisting of polyenes, imidazoles and triazoles. [0013] In yet another embodiment of the invention, the antiviral agent is selected from the group consisting of Zidovudines, idouridine, acyclovir and ribavarine. [0014] In another embodiment of the invention, the 3′,5-Dihydroxy flavone 7-O-β-D-galacturonide-4′-O-β-D-glucopyranoside is used in pure form or in the form of a HPLC fingerprinted fraction of 3′,5-Dihydroxy flavone 7-O-β-D-galacturonide-4′-O-β-D-glucopyranoside from Cuminum cyminum or a sub fraction. [0015] In another embodiment of the invention, the concentration of the anti infective is two to eight times lesser than when such anti infective is used without the bioenhancer. [0016] In another embodiment of the invention, the composition includes one or more pharmaceutically acceptable additives and excipients. [0017] In another embodiment of the invention, the additives/excipients are selected from the group consisting of nutrients comprising proteins, carbohydrates, sugar, talc, magnesium stearate, cellulose, calcium carbonate, starch-gelatin paste, and/or pharmaceutically acceptable carriers, diluents and solvents. [0018] In another embodiment of the invention, the composition is in oral administration form. [0019] In a further embodiment of the invention, the ratio of the anti-infective to the bioenaancer is in the range of 1:1 to 1:5. [0020] In yet another embodiment of the invention, the additives have no effect on the antiinfective property of the said composition. [0021] The present invention also provides a process for the preparation of a composition useful for enhanced therapeutic effect at reduced doses of the anti infectives against infection caused bya microorganism comprising a mixture of an anti-infective agent and a bioenhancer selected from piperine of formula 1 and 3′,5-Dihydroxy flavone 7-O-β-D-galacturonide-4′-O-β-D-glucopyranoside of formula 2 or a mixture thereof, said process comprising a physical admixing technique. [0022] In one embodiment of the invention, the physial admixing technique is selected from dialysis, molecular sieving and by membranes. [0023] In another embodiment of the invention, the process of preparation of the bioenhancer comprises use of water, alcohol, combinations of water and alcohol, hydrocarbons, ketones and ethers. [0024] In one embodiment of the invention, the anti infective agent is selected from the group consisting of penicillins including semi synthetic, cephalosporins, aminoglycosides, glycopeptides, fluroquinolones, macrolides, tetracyclines, first and second line anti-TB drugs, antileprosy drugs, oxazolidelones, antifungal agents, antiviral agents and pyrimidine derivatives—sulphonamides combination, [0025] In a further embodiment of the invention, the anti-fungal agent is selected from the group consisting of polyenes, imidazoles and triazoles. [0026] In yet another embodiment of the invention, the antiviral agent is selected from the group consisting of Zidovudines, idouridine, acyclovir and ribavarine. [0027] In another embodiment of the invention, the 3′,5-Dihydroxy flavone 7-O-β-D-galacturonide-4′-O-β-D-glucopyranoside is used in pure form or in the form of a HPLC fingerprinted fraction of 3′,5-Dihydroxy flavone 7-O-β-D-galacturonide-4′-O-β-D-glucopyranoside from Cuminum cyminum or a sub fraction. [0028] In another embodiment of the invention, the concentration of the anti infective is two to eight times lesser than when such anti infective is used without the bioenhancer. [0029] In another embodiment of the invention, the composition includes one or more pharmaceutically acceptable additives and excipients. [0030] In another embodiment of the invention, the additives/excipients are selected from the group consisting of nutrients comprising proteins, carbohydrates, sugar, talc, magnesium stearate, cellulose, calcium carbonate, starch-gelatin paste, and/or pharmaceutically acceptable carriers, diluents and solvents. [0031] In another embodiment of the invention, the composition is in oral administration form. [0032] In a further embodiment of the invention, the ratio of the anti-infective to the bioenhancer is in the range of 1:1 to 1:5. [0033] In yet another embodiment of the invention, the additives have no effect on the anti-infective property of the said composition. BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS [0034] [0034]FIG. 1 is antimicrobial composition of the invention according to the checker board method. [0035] [0035]FIG. 2 is a graph showing the effect of rifampicin alone and in combination with piperine in an in vivo mice infection model. [0036] [0036]FIG. 3 is a graph showing the effect of rifampicin alone and in combination with 3′,5-Dihydroxy flavone 7-O-β-D-galacturonide-4′-O-β-D-glucopyranoside of formula 2 in in vivo mice infection model. DETAILED DESCRIPTION OF THE INVENTION Bioefficacy/Bioavailability [0037] Studies originating from the laboratory of the inventors resulted in conceptualisation of ‘bioenhancers’ wherein such agents, which by themselves are not therapeutic entities but when combined with an active drug lead to the potentiation of the pharmacologic effect of the drug. Such formulations have been found to increase the bioavailability/bioefficacy of a number of drugs even when reduced doses of drugs are present in such formulations. Evidence have been obtained for such classes of drugs which are (a) poorly bioavailable and/or efficacious, (b) require prolonged therapy, and (c) are highly toxic and expensive. For example, Patent nos IP 172690, IP 176433 and U.S. Pat. No. 5,744,161 disclose such art. Further studies carried out in the laboratory of the inventors have shown that such bioenhancers are not only capable of increasing bioavailability of a wide variety of therapeutic agents but are also capable of enhancing bioefficacy through a variety of mechanisms underscored in serial nos (a) to (g) below. As a result newer understanding has emerged about the factors involved in decreased cellular concentrations of drugs at which they fail to attain therapeutic levels and the strategies that make it possible to enhance the bioavailability and/or bioefficacy of these active drugs even at lower concentrations compared to standard high dosing. Some of these factors are: [0038] (a) Increasing the penetration or entry of the active drug into the pathogen even where they become persistors, besides inhibiting the capability of pathogens and abnormal tissues to reject the drug. This would eventually ensure the enhanced killing of the pathogenic microorganisms, which are otherwise inaccessible to the active drug. [0039] (b) Chemoresistance is a major problem in drug therapy. The mechanisms underlying the clinical phenomena of de novo and acquired drug resistance may arise from alterations at any step in the cell-killing pathway. These include drug transport, drug metabolism, drug targets, cellular repair mechanisms and the ability of cells to recognize a harmful toxin or pathogen. A common mechanism of reduced cellular drug accumulation is the increased expression of P-glycoprotein, a membrane transporter that efficiently removes drugs from these cells. Another limiting factor is the high activity of cytochrome P 450 dependent proteins. Both these proteins P-gp and CYP 450 have been shown to regulate the oral bioavailability of a majority of drugs. P-gp is considered to be associated with MDR caused by the levels of its expression in tumors and after drug therapy. [0040] (c) Modifying the signalling process to ensure increased accessibility of drugs to the pathogens. Considerable evidence is accumulating to suggest that calcium signalling plays a major role in the therapeutic action of several drugs, which are effluxed by P-gp independent pathways. (Vilpo et al, Haematologica 2000:85:806-813). cAMP mediated signal pathways on the other hand are associated with an alteration in membrane fluidity (Friedlander G et al, Biochimica et Biophysica Acta 1990; 1022:1-7). [0041] (d) Immunological intervention through NO production, CMI and/or humoral immune potentiation with favourable influence on the Th 1/Th 2 balance. [0042] (e) Sensitization of specific receptors like proteins, DNA, RNA etc thus potentiating and prolonging the effect leading to enhanced antibiotic activity aghast pathogens, and disorders Adequate experimental evidences have been gained in respect of several of these mechanisms. For example, piperine has been shown to intercalate deeply into the phospholipids of the cell membrane, (Ray et al, Ind. J Biochem. Biophys 1999; 36: 248-251) modulating the membrane fluidity, which may alter the activity of membrane bound transporter proteins. The overall permeability changes may affect (i) specific ion transporter channels, and (ii) also lead to bulk movement of lipophilic solutes along the paracellular pathway. Such membrane changes have also been evidenced in the action of several polyene antibiotics (Milhaud J et al, Biochimica et Biophysica Acta, 1988; 943:315-325). However, the changes caused by piperine in membrane fluidity are, as already stated, short living, completely reversible but more than any thing is selective. Had it not been so, serious side effects and toxicity should have manifested themselves during phase II and phase III clinical trials of reduced dose formulation of anti-TB drugs wherein piperine was admisistered daily for six months at 10 mg dose vis-à-vis standard dose anti-TB drugs without piperine. The black pepper containing piperine is a part of food practically all over the world. The average amount of pepper consumed per capita will account for piperine content much more than the amount used in these formulations of present invention. [0043] (f) Potentiating the mechanism of action of drugs and thus increasing their efficacy at lower doses e.g. inhibition of RNA polymerase transcription leading to potentiation of the effect of rifampicin at less than half the standard dose. [0044] (g) Enhancing the absorption and/or inhibiting biotransformation of drugs thereby increasing bioavailability of drugs. [0045] The products of the present invention are novel mechanism based pharmaceutical entities acting through synergism and or additive effect so that drugs contained in the formulation are more bioefficaceous as a result of one or more of the mechanism as revealed above and thereby increasing the sensitivity of the target cell to an anti-infective. DESCRIPTION OF THE FORMULATIONS CONTAINING BIOENHANCER [0046] The ‘drug’ in the present invention refers to a chemical entity capable of affecting organism's patho-physiology and used for the treatment or prevention of disease. Drugs include a number of classes of compounds, but not limited to aminoglycoside, penicillins, cephalosporins and other β-lactam agents, macrolides, glycopeptides, fluoroquinolones, tetracyclines, first and second line anti-TB drugs, anti-leprosy, antivirals, polyene, triazole, and imidazoles and combinations like pyrinidines, sulphamethoxazole. Drugs may be a pro-drug, activated or metabolised form, consisting of charged, uncharged, hydrophilic, hydrophobic or zwitter-ion species which make their entry by simple diffusion, carrier mediated transport dependent and not dependent on energy requirements, through ion and/or voltage gated channels. [0047] The ‘bioenhancer’ refers to piperine (formula 1) or other such molecules, characterised fractions and/or extracts as a chemical entity. The process of obtaining piperine as more than 98% pure chemicaly characterized form has been disclosed in IP 172689, IP 172690, IP 176433, U.S. Pat. No. 5,439,891 and a co-pending U.S. patent application Ser. No. 60/306917/2001. The processes for preparation of a characterised fraction (BPLC profile enclosed) and a pure chemically characterised molecule (FIG. 2) from Cuminum cyminum have been disclosed in co-pending patent application No. NF 515/2001, The ratio of those two bioenhancers to drugs may vary from 1 to 50% for the fraction and from 0.1 to 30% for the pure molecule to obtain desired reduction in MIC values anti infectives. The ratios of the drug and the bioenhancers and/or in composite bioenhancers are governed by amounts sufficient to produce enhanced therapeutic efficacy as measured by MIC of the formulation being lesser than the drug alone. A pharmaceutical carrier is generally an inert bulk agent added to make the ingredients achieve superior admixing and can be solid or liquid. The inert parts of standard pharmaceutical compositions used in this process are also part of the present invention. Study Design [0048] The checkerboard method: [0049] This is the most frequently used method to access the antimicrobial combinations in vitro. The term “checkerboard” refers to the pattern (of tubes or microtiter plate wells) formed by multiple dilutions of two drugs being tested (Eliopoulos G M, Moellering R C. Antimicrobila Combinations. In: Antibiotics in Laboratory Medicine: USA: Williams & Wilkins). In the present study the checkerboard consisted of columns in which each tube (or well) contains the same amount of the standard drug (antibacterial/antifungal/anti-TB/antiviral) being diluted along the x-axis and rows in which each tube (or well) contains the same amount of the bioenhancer being diluted on the y-axis (FIG. 3). As a result each square in the checkerboard (which represents one tube/well or plate) contained a unique combination of the standard drug and bioenhancer. The concentration range of standard drug in the present study was 64 μg/ml to 0.03 μg/ml, whereas the bioenhancer was tested in the range of 500 μg/ml to 0.2 μg/ml. This checkerboard technique can be performed with liquid or semisolid (agar) media. [0050] Agar Method: [0051] In this method the agar (Mueller Hinton agar, Middlebrook 7H10 agar) was autoclaved and allowed to cool to 50° C. to 55° C. The combination of the standard drug and the bioenhancer was added to the agar. Serial two fold dilutions of each of standard drug and the bioenhancer were prepared in appropriate solvents. In order to maintain the desired concentrations of both agar and drugs, and to rule out the effect of solvent, the volume of solvent (containing standard drug or bioenhancer) added to agar was kept small (i.e ≦5% of the total volume). After the agar plates have been poured and allowed to dry, the bacteria to be tested were applied to the suface of agar with a replicating device designed to deliver a standard inoculum (approx 10 4 cfu|spot). The plates were incubated at 37° C. for 24 hrs (3 weeks in case of Mycobacterium tuberculosis ) [0052] Broth Method: [0053] The above-mentioned checkerboard was also performed with liquid media in a microtiter plate format. This method was used to study the combination of antibacterial/antifingal/antiviral drugs with bioenhancer. Inihibitory Effect of Bioenbancers [0054] All bioenhancers were evaluated for their own inhibitory effect if any, at a concentration range of 500 μg/ml to 0.2 μg/ml. (Table 1, 2, & 3) TABLE 1 Effect of Piperine on Microorganisms OrganismsConc. of piperine μg/ml 0.2 0.8 3.12 12.5 50 100 Staphylococcus aureus ATCC ++++ ++++ ++++ ++++ ++++ +++ 29313 Methicillin Resistant ++++ ++++ ++++ ++++ ++++ +++ Staphylococcus aureus (MRSA) Staphylococcus epidermidis ++++ ++++ ++++ ++++ +++ ++ ATCC 12228 Staphylococcus hemolyticus ++++ ++++ ++++ ++++ +++ ++ ATCC 29978 Bacillus cereus RRL 02 ++++ ++++ ++++ ++++ ++++ ++++ Escherichia coli ATCC 25922 ++++ ++++ ++++ ++++ ++++ ++++ Salmonella typhi AIIMS 2 ++++ ++++ ++++ ++++ ++++ ++++ Klebsiella pneumoniae ++++ ++++ ++++ ++++ ++++ ++++ ATCC 75388 Pseudomonas aeruginosa ++++ ++++ ++++ ++++ ++++ ++++ ATCC 27583 Candida albicans ++++ ++++ ++++ ++++ ++++ +++ ATCC 90028 Candida parapsilosis ++++ ++++ ++++ ++++ ++++ +++ ATCC 22019 Candida glabrata ++++ ++++ ++++ ++++ ++++ +++ ATCC 90030 Candida tropicalis ATCC 750 ++++ ++++ ++++ ++++ ++++ +++ Candida krusei ATCC 6258 ++++ ++++ ++++ ++++ ++++ +++ Aspergillus flavus ++++ ++++ ++++ ++++ +++ ++ MTCC 1973 Aspergillus fumigatus SI-1 ++++ ++++ ++++ ++++ +++ ++ Mycobacterium tuberculosis ++++ ++++ ++++ ++++ ++++ ++++ H 37 Rv Mycobacterium tuberculosis ++++ ++++ ++++ ++++ ++++ ++++ 615 Mycobacterium avium ATCC ++++ ++++ ++++ ++++ ++++ ++++ 49601 Mycobacterium intracelluare ++++ ++++ ++++ ++++ ++++ ++++ ATCC 13950 [0055] [0055] TABLE 2 Effect of fraction of Cuminum cyminum on Micro organisms Conc. of fraction of Cuminum cyminum 0.5 2.0 8.0 31.2 125 500 Organisms μg/ml μg/ml μg/ml μg/ml μg/ml μg/ml Staphylococcus aureus ATCC ++++ ++++ ++++ ++++ ++++ ++++ 29313 Methicillin Resistant ++++ ++++ ++++ ++++ ++++ ++++ Staphylococcus aureus (MRSA) Staphylococcus epidermidis ++++ ++++ ++++ ++++ ++++ ++++ ATCC 12228 Staphylococcus. hemolyticus ++++ ++++ ++++ ++++ ++++ ++++ ATCC 29978 Bacillus cereus RRL 02 ++++ ++++ ++++ ++++ ++++ ++++ Escherichia coli ATCC 25922 ++++ ++++ ++++ ++++ ++++ ++++ Salmonella typhi AIIMS 2 ++++ ++++ ++++ ++++ ++++ ++++ Klebsiella pneumoniae ATCC ++++ ++++ ++++ ++++ ++++ ++++ 75388 Pseudomonas aeruginosa ++++ ++++ ++++ ++++ ++++ ++++ ATCC 27583 Candida albicans ++++ ++++ ++++ ++++ ++++ ++++ ATCC 90028 Candida parapsilosis ++++ ++++ ++++ ++++ ++++ ++++ ATCC 22019 Candida glabrata ++++ ++++ ++++ ++++ ++++ ++++ ATCC 90030 Candida tropicalis ATCC 750 ++++ ++++ ++++ ++++ ++++ ++++ Candida krusei ATCC 6258 ++++ ++++ ++++ ++++ ++++ ++++ Aspergillus flavus ++++ ++++ ++++ ++++ ++++ ++++ MTCC 1973 Aspergillus fumigatus SI-1 ++++ ++++ ++++ ++++ ++++ ++++ Mycobacterium tuberculosis ++++ ++++ ++++ ++++ ++++ ++++ H 37 Rv Mycobacterium tuberculosis ++++ ++++ ++++ ++++ ++++ ++++ 615 Mycobacterium avium ATCC ++++ ++++ ++++ ++++ ++++ ++++ 49601 Mycobacterium intracelluare ++++ ++++ ++++ ++++ ++++ ++++ ATCC 13950 [0056] [0056] TABLE 3 Effect of pure molecule of Cuminum cyminum on Micro organisms Conc. of pure molecule of Cuminum cyminum μg/ml Organisms 0.2 0.8 3.12 12.5 50 100 Staphylococcus aureus ATCC ++++ ++++ ++++ ++++ ++++ ++++ 29313 Methicillin Resistant ++++ ++++ ++++ ++++ ++++ ++++ Staphylococcus aureus (MRSA) Staphylococcus epidermidis ++++ ++++ ++++ ++++ ++++ ++++ ATCC 12228 Staphylococcus , hemolyticus ++++ ++++ ++++ ++++ ++++ ++++ ATCC 29978 Bacillus cereus RRL 02 ++++ ++++ ++++ ++++ ++++ ++++ Escherichia coli ATCC 25922 ++++ ++++ ++++ ++++ ++++ ++++ Salmonella typhi AIIMS 2 ++++ ++++ ++++ ++++ ++++ ++++ Klebsiella pneumoniae ATCC ++++ ++++ ++++ ++++ ++++ ++++ 75388 Pseudomonas aeruginosa ++++ ++++ ++++ ++++ ++++ ++++ ATCC 27583 Candida albicans ++++ ++++ ++++ ++++ ++++ ++++ ATCC 90028 Candida parapsilosis ++++ ++++ ++++ ++++ ++++ ++++ ATCC 22019 Candida glabrata ++++ ++++ ++++ ++++ ++++ ++++ ATCC 90030 Candida tropicalis ATCC 750 ++++ ++++ ++++ ++++ ++++ ++++ Candida krusei ATCC 6258 ++++ ++++ ++++ ++++ ++++ ++++ Aspergillus flavus ++++ ++++ ++++ ++++ ++++ ++++ MTCC 1973 Aspergillus fumigatus SI-1 ++++ ++++ ++++ ++++ ++++ ++++ Mycobacterium tuberculosis ++++ ++++ ++++ ++++ ++++ ++++ H 37 Rv Mycobacterium tuberculosis ++++ ++++ ++++ ++++ ++++ ++++ 615 Mycobacterium avium ATCC ++++ ++++ ++++ ++++ ++++ ++++ 49601 Mycobacterium intracelluare ++++ ++++ ++++ ++++ ++++ ++++ ATCC 13950 EXAMPLES [0057] The following examples are intended to demonstrate some of the preferred embodiments but in no way be construed so as to limit the scope of the invention. Any person skilled in the art can design more formulations, which may be considered as part of the present invention. Example 1 Preparation of Colourless, Non-pungent 99% Pure Piperine [0058] This was done by the process claimed in Indian Patents 1726891 and IP 172690 and U.S. Pat. No. 5,439,891 and U.S. application Ser. No, 60/306917/2001, which is incorporated herein by reference. Example 2 Decrease in the MICs of Rifampicin Against M. tuberculosis, M. avium and M. intracellure When Used in Combination with Piperine and Fraction of Cuminum cyminum [0059] Minimum Inhibitory Concentration (MIC) of rifampicin alone and in combination with piperine was performed against Mycobacterial species, using method described in the study design. [0060] Two-fold reduction in MIC of rifampicin was observed in combination with piperine and fraction of Cuminum cyminum (Table 4-a, 4-b) Example 3 Reduction in the Dose Requirement of Rifampicin When Used in Combination with Piperine and Fraction of Cuminum cyminum in Systemic Infection Model of Mice [0061] The study was conducted to see the in vivo response of rifampicin in combination with piperine. The Swiss albino mice were infected intravenously with M. tuberculosis H 37 Rv (10 6 CFU/mouse). The infected mice were divided in groups and each group consisted of 6 mice. [0062] The treatment started 24 hrs post infection and continued for 4 weeks in once a day for 5 days in a week dosing schedule. The mice were sacrificed after 4 weeks and the CFU was enumerated from the lungs and the spleen. Rifampicin alone at 20 mg/kg was able to bring about 2-log deduction in log 10 CFU. Same effect was observed with rifampicin at 10 mg/kg when given in combination with pipette at 20 mg/kg. Whereas fraction of Cuminum cyminum was more effective as it yielded the same reduction in log 10 CFU at 5 mg/kg dose of rifampicin. (FIGS. 4 - a , 4 - b ) TABLE 4-a MICs of Rifampicin alone and in combination with piperine MIC (μg/ml) Rif + Rif + Rif + Rif + 50 S.No Organisms Rif 0.09 μg/ml 0.78 μg/ml 6.25 μg/ml μg/ml 1. M tuberculosis 0.12 0.03 0.03 0.06 0.12 H 37 Rv 2. M tuberculosis 0.06 0.03 0.03 0.03 0.03 611 3. M tuberculosis 0.06 0.03 0.03 0.03 0.03 615 4. M tuberculosis 0.12 0.06 0.03 0.03 0.03 616 5. M avium 2.0 0.5 0.5 0.5 0.5 ATCC 49601 6. M intracellure 2.0 2.0 1.0 1.0 1.0 ATCC 13950 [0063] [0063] TABLE 4-b MICs of Rifampicin alone and in combination with fraction of Cuminum cyminum . MIC (μg/ml) Rif + Rif + Rif + Rif + 50 S.No Organisms Rif 0.09 μg/ml 0.78 μg/ml 6.25 μg/ml μg/ml 1. M tuberculosis 0.12 0.03 0.03 0.03 0.03 H 37 Rv 2. M tuberculosis 0.06 0.03 0.03 0.03 0.03 611 3. M tuberculosis 0.06 0.03 0.03 0.03 0.03 615 4. M tuberculosis 0.12 0.06 0.06 0.06 0.06 616 5. M avium 2.0 1.0 1.0 0.1 1.0 ATCC 49601 6. M intracellure 2.0 1.0 1.0 1.0 1.0 ATCC 13950 Example 4 Decrease in the MICs of Ciprofoxacin Against Staphylococcus aureus, MRSA and Staphylococcus hemolyticus When Used in Combination with Piperine [0064] Minimum Inhibitory Concentration (MIC) of ciprofloxacin alone and in combination with piperine was performed against bacterial species, using method described in the study design. Two to more than eight fold reductions in MIC of ciprofloxacin was observed in combination with piperine. (Table-5) TABLE 5 MICs of Ciprofloxacin alone and in combination with piperine. MIC (μg/ml) Cipro + P- Cipro + P- Cipro + P- S. No Organisms Cipro 12.5 μg/ml 50 μg/ml 100 μg/ml 1. S aureus ATCC 0.5 0.2.5 0.25 0.06 29313 2. MRSA 450 64 64 32 16 3. MRSA 15187 64 32 16 8 4. S epidermidis 0.25 0.25 <0.03 <0.03 ATCC 12228 5. S hemolyticus 0.25 0.12 0.12 <0.03 ATCC 29978 Example 5 Decrease in the MICs of Fluconazole Against Candida albicans, Candida parapsilosis and Candida glabrata When Used in Combination with Piperine [0065] Minimum Inhibitory Concentration (MIC) of fluconazole alone and in combination with piperine was performed against fungal species, using method described in the study design Two to eight fold reductions in NGC of fluconazole was observed in combination with piperine. (Table-6) TABLE 6 MICs of Fluconazole alone and in combination with piperine (P) MIC (μg/ml) FCZ + P FCZ + P FCZ + P FCZ + P FCZ + P Fungal Cultures FCZ 1.56 μg/ml 6.25 μg/ml 12.5 μg/ml 25 μg/ml 50 μg/ml Candida albicans 2.0 2.0 2.0 2.0 2.0 1.0 A261 Candida albicans 0.5 1.0 0.5 0.25 0.25 <0.12 ATCC90028 Candida 16 16 16 8.0 2.0 1.0 parapsilosis ATCC22019 Candida glabrata 16 16 16 4.0 2.0 1.0 ATCC 90030 Example 6 List of Drugs Cited in Accompanying Table 7 as Some of the Examples for the Purpose of the Present Invention REFERENCES [0066] 1. Gutman L T. The use of TMP-SMX in children: a review of adverse reactions and indications. Pediatr Infect Dis 1984; 3;349-57. [0067] 2. Bushby S R M. Synergy of trimethoprim and sulfonamides: History and current status. In: Antibiotics and Antibiosis in Agriculture, London: Butterworths. 1977; 64-81. [0068] 3. Olin B R, ed. Drug Facts and Comparisons. St. Louis, Facts and Comparisons, Inc.; 1998: 408b-409d. [0069] 4. Cockerill F R, Edson R S. TMP-SMX. Mayo Clin Proc 199 1; 66:1260-9. TABLE 7 MIC (μg/ml) Piperine Pure molecule of C. cyminum Fraction of C. cyminum Drug Drug + % Drug Drug + % Drug Drug + % Drugs Organisms alone BE decrease alone BE decrease alone BE decrease Fluroquinolones Ciprofloxacin Gram positive bacteria 0.12-32 0.06-8 50-76 0.12-32 0.06-8 50-76 0.12-32 0.12-16 0-50 Gram negative bacteria 0.03-0.5 0.03-0.25 0-50 0.03-0.5 0.03-0.12 0-76 0.03-0.5 0.03-0.25 0-50 M. tuberculosis 0.5-1 0.25-0.5 50 0.5-1 0.25-0.5 50 0.5-1 0.5-1 0 Ofloxacin Gram positive bacteria 0.12-32 0.06-8 50-76 0.12-32 0.06-8 50-76 0.12-32 0.12-32 0 Gram negative bacteria 0.06-32 0.03-16 50 0.06-32 0.03-16 50 0.06-32 0.06-32 0 M. tuberculosis 0.5-2.5 0.5-1.25 0-50 0.5-25 0.5-1.25 0-50 0.5-2.5 0.5-2.5 0 Norfloxacin Gram positive bacteria 0.12-32 0.06-4 50-97 0.12-32 0.06-8 50-76 0.12-32 0.12-32 0 Gram negative bacteria 0.03-64 0.03-32 0-50 0.03-64 0.03-64 0 0.03-64 0.03-64 0 Cephalosporins Cefaclor Gram positive bacteria 0.06-32 0.03-16 50 0.06-32 0.06-32 0 0.06-32 0.06-16 0-50 Gram negative bacteria 0.25-64 0.25-32 0-50 0.25-64 0.25-64 0 0.25-64 0.25-32 0-50 Cefdinir Gram positive bacteria 0.06-32 0.06-32 0 0.06-32 0.06-32 0 0.06-32 0.03-16 50 Gram negative bacteria 0.25-64 0.25-64 0 0.25-64 0.25-64 0 0.25-64 0.12-32 50 Ceftrioxone Gram positive bacteria 0.12-32 0.06-8 50-76 0.12-32 0.12-16 0-50 0.12-32 0.06-8 50-76 Gram negative bacteria 0.03-32 0.03-16 0-50 0.03-32 0.03-16 0-50 0.03-32 0.01-8 50-76 Cefpedoxime Gram positive bacteria 0.12-16 0.06-8 50 0.12-16 0.12-8 0-50 0.12-16 0.06-8 50-76 Gram negative bacteria 0.03-64 0.03-32 50 0.03-64 0.03-32 0-50 0.03-64 0.01-32 50-76 Aminoglycosides Amikacin Gram positive bacteria 2-32 2-16 0-50 2-32 1-16 50 2-32 2-16 0-50 Gram negative bacteria 0.12-4 0.06-2 50 0.12-4 0.06-2 50 0.12-4 0.06-2 50 M. tuberculosis 0.5-1 0.25-0.5 50 0.5-1 0.5-0.5 0-50 0.5-1 0.5-0.5 0-50 Gram positive bacteria Gram negative bacteria 0.004-64 0.004-64 0 0.004-64 0.004-16 0-76 0.004-64 0.004-16 0-76 Anti TB Isoniazid M. tuberculosis 0.12-32 0.06-8 50-76 0.12-32 0.06-16 50 0.12-32 0.12-32 0 Rifampicin M. tuberculosis 0.06-0.5 0.03-0.1 50-76 0.06-0.5 0.01-0.12 76 0.06-0.5 0.01-0.12 76 Pyrazinamide M. tuberculosis 6-60 6-30 0-50 6-60 3-30 50-76 6-60 3-30 50-76 Ethambutol M. tuberculosis 1-5 1-0.25 0-50 1-5 1-5 0 1-5 1-5 0 Glycopeptides Vancomycin Gram positive 0.03-8 0.01-4 50 0.03-8 0.03-8 0 0.03-8 0.03-8 0 bacteria Anti fungal Fluconazole Yeast 0.12-64 0.06-32 50 0.12-64 0.12-64 0 0.12-64 0.12-64 0 Ketoconazole Yeast 0.12-0.5 0.12-0.25 0-50 0.12-0.5 0.06-0.12 50-76 0.12-0.5 0.12-0.25 50 Filamentous fungi 0.25-2 0.25-2 0 0.25-2 0.12-1 50 0.25-2 0.25-2 0 Amphotericin B Yeast 0.25-2.0 0.12-1 50 0.25-2.0 0.12-0.5 50-76 0.25-2.0 0.12-0.5 50-76 Filamentous fungi 0.25-4 0.25-2 0-50 0.25-4 0.12-2 50 0.25-4 0.12-2 50
The present invention relates to the use of bioenhancers to decrease the resistance of microbial strains to anti-infective such an antibiotics and antifungals by potentiating the activities of anti-infective. This may be usefuil to reduce resistance in bacteria and yeast to aid in the treatment of certain infections and disease and to lower the concentration of antiinfectives necessary to inhibit the growth of microbial strains.
0
FIELD OF THE INVENTION This invention relates to solids exclusion. More particularly, this invention relates to a solids exclusion system that includes a filter characterized by porosity and permeability designed to optimize production at multiple specified intervals, and made of materials resistant to erosion by any solids and/or resistant against corrosion by any chemicals commonly used in drilling, or produced from, and/or injected into a well. In addition, the present invention makes it possible to circulate flow at the outside of the filter to remove any solids and/or fluids which can accumulate and prohibit flow; and, further, it can be employed to inject or produce any fluid and/or solids outside the filter. The invention can be used in any bore hole, lined or open hole, into any earth formation whether it is used for injection, production, and/or circulation of fluids, solids or any combination thereof. BACKGROUND OF THE INVENTION In the production of hydrocarbons from earth formations, wellbores are drilled into reservoirs or pay zones. Such wellbores are completed and perforated at one or more zones to recover hydrocarbons from reservoirs. Many oil and gas wells produce fluid from underground formations containing solid particles, which are loose and/or not strongly attached to each other and when hydrocarbon-containing fluid is produced, it tends to carry entrained solids with it. These solids can cause serious damage to well equipment due to erosion. Erosion is particularly bad when a disproportionate amount of flow is concentrated in a relatively small region, resulting in high velocities of the solids. These regions are called “hot spots”. Filters, normally called sand screens of various designs, and slotted liners are commonly placed opposite the formation and below the production tubing in the well bore preventing entry of solid particulates into the tubing. Filters of different makes and configurations are commonly used as solids control devices. Filters currently available in the art typically erode substantially over time. In addition, they cannot effectively produce all zones because of the fact that the pressure differential required varies over the zones, which creates “hot spots” as mentioned above. Furthermore, there is currently no method available of filter cleaning by circulation of fluids, with or without additives, outside the filter. Filters are commercially available that are made of multiple layers of woven material sintered together into a porous rigid medium, however they are only available in several mesh sizes with only one mesh size available per filter, and they are subject to corrosion and/or erosion. There is a great need in the art for a solid filter assembly that is resistant to all erosive chemicals and production fluids known in the petroleum industry to cause problems and that can deal effectively with all sizes of solids to optimize production, even where optimal production requires different permeabilities and porosities of the filter for different intervals vertically or radially. It would constitute a great advance in the art if the same filter assembly were designed such that well intervention and cleaning were possible by circulation at the outside of the filter. SUMMARY In accordance with the foregoing the present invention provides a solids exclusion system with features not currently available in the art, including being constructed of material resistant to erosion by any known fluids with or without any form of solids, and characterized by porosity and permeability targeted for optimal production in multiple zones, and an overall design that makes possible circulation at the outside of the filter to enable cleaning, and which likewise makes possible the injection or production of any fluid and/or solids from outside the filter. The present invention is a solids exclusion system for preventing migration of solid particles, of a certain size, into a production well comprising a filter having an upper surface and a lower surface, positioned in a lined or unlined hole, characterized by variable porosity and permeability properties designed to optimize production at one or more intervals, and further comprising the filter is constructed of a material resistant to erosion by any chemicals commonly used in the petroleum industry or any naturally occurring well bore fluids produced from earth formations. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a longitudinal, cross-section view of one embodiment of the present invention. FIG. 2 is an enlarged view of one section of FIG. 1 showing a seal. FIG. 3 is a longitudinal, cross-section view of one embodiment showing a sub-section of the screen with connections, pin and box at each end. DETAILED DESCRIPTION OF THE INVENTION The solids exclusion system of the present invention can be deployed in a well bore in an earth formation that is lined or unlined with steel or any other material. The first embodiment and key part of the solids exclusion system is a filter made of erosion resistant material having selected porosity, permeability and other flow characteristics for one or more specific intervals. The filter is manufactured in such a manner that the porosity and permeability can have selected values in both radial as well as longitudinal direction. This will enable the free passage of solids through the body of the filter, after they have passed the wall of the filter. There can be at least two versions of the solids exclusion system, one for allowing flow from outside in, having a lower porosity outside than inside, and one from inside out having a lower porosity inside than outside. Also porosity and permeability differences in the vertical direction can be achieved by the manufacturing process, thus allowing programmable flow resistance in longitudinal direction along the filter axis. The filter is composed of materials that are erosion resistant to any naturally occurring well bore fluid produced from earth formations. Furthermore, the filter is resistant against all commercially available acids used in the petroleum and natural gas industry, including, but not limited to HCl and HF. Materials that would possess that level of erosion resistance include, but are not limited to metals, organic and/or non-organic porous permeable materials. Said metals, organic and/or non-organic porous permeable materials that are sintered and/or atomically bonded are particularly suitable. Examples of each of those are sintered and/or atomically bonded steel or copper, sintered and/or atomically bonded carbon and various sintered and/or atomically bonded ceramics. Sintered and/or atomically bonded material has properties that make it a particularly desirable choice. These can be provided in tubular form and can be made to specific porosity and permeability specifications. Sintered and/or atomic bonded materials can be quite weak in tensile and shear. This can be resolved, if deemed necessary, by steel or other reinforcements stipulated by the design of the assembly. Another very attractive embodiment is that the novel solids exclusion system design of the present invention is part of an assembly that makes it possible to circulate flow at the outside of the filter by opening ports above and below the filter that permit fluid communication from inside the filter to the outside of the filter, or visa versa, to allow cleaning at the outside and removal of any impairment by means of circulation. This cleaning operation can be set in motion, in part, by contacting a heating coil with shape memory metal alloy rods. In the specification and claims, the term “shape memory alloy” is used to refer to an alloy that exhibits a shape-memory effect, wherein complete recovery of a deformation undergone at a particular temperature takes place at heating. The skilled person is able to select a composition of the alloy material that exhibits the required effects at the temperature prevailing in the well. The solids exclusion system contains an internal sealing arrangement above the filter and an internal sealing arrangement below the filter, allowing injection of fluids below the filter entering the annular space between the solids exclusion system and the lined or unlined well bore, thereby enabling fluid transport at the outside of the filter, taking the returns at the top of the filter through the sealing arrangement located at that position, or visa versa. Also within the scope of the present invention it is contemplated that a larger solids exclusion system can be comprised of multiple filter sections vertically being pressure separated from each other in the annular space between the individual filters, or filter sections, and lined or not lined well bore in an earth formation. Each filter section can consist of several sub filter sections, which might have different physical properties. Further, the present invention contemplates the use of an internal (over the filter) straddling arrangement enabling selective movement of fluids in- or outwards of the filter or filter parts. This enables localized cleaning and/or movement from fluids of any type and property. Each filter can be fitted with one polished bore at the top of the filter or filter sections and one at the bottom thereby enabling full straddling of that section resulting in zero production or injection, thereby providing a method of reservoir management. The solids exclusion system can have an external sealing design on top of the filter and/or filter subsections and one below the filter or filter subsections thereby sealing the annular space between the solids exclusion system and the lined or not lined well bore, thereby blocking annular communication along the filter top and bottom. The external seals can be activated in such a manner that vertical movement of the solid exclusion system is zero at any given time of the activation process. This activation is made possible by the use of shape memory alloy as an activation means. (See WO0111185, WO0138692, incorporated by reference herein in the entirety.) Within the scope of the present invention, the design of the solids exclusion system and especially the design of the external seals (See FIG. 2 ) can be configured in such a manner that all external seals can be deactivated without drilling or so-called “over washing” of the solids exclusion system. The latter can be achieved by using a coiled tubing and/or wireline unit to cut the section 5 ( FIG. 2 ) at the position between the arrows 22 b and 22 c until that point that the memory metal bars ( 22 c ) are being cut. This will release the force from the elastomeric seal element 22 b. The solids exclusion system can be held in place during its lifetime by at least one anchor, commonly a packer, at the bottom, and in case of tubing less completion, one non-rig/hoist intervention comprising an additional anchor, commonly a packer, at the top of the solids exclusion system. It is desirable to obtain a water and/or hydrocarbon liquid flow through the permeable, porous and/or non-sealing parts of typically from 0 up to about 50 cubic meters liquid per day per meter of filter. It is desirable to obtain a flow of water and/or natural gas through the permeable, porous and/or non-sealing parts of typically from 0 to about 20,000 standard cubic meters gas per day per meter filter. The solids exclusion system, and specifically the filter, should suitably allow passage of liquid of any density to a maximum of a density of typically 2.0 kg/liter at a maximum flow rate of typically 5 cubic meters per day per meter filter. Fluids of this type are typically used during installation and/or other well bore intervention activities. The solids exclusion system is designed so that it can be installed and/or retrieved using state of the art industry rig and/or hoist equipment, procedures, and standards. The length of the solids exclusion system, or subsections thereof, will preferably not exceed the length of about typically 10 meters. A suitable overall diameter of the solids exclusion system at any given position is less than the smallest drift diameter of the pipe through which the solids exclusion system must fully or partially pass. Sizes and tolerances for the pipe may vary. In yet another embodiment of the present invention the solids exclusion system with circulation capabilities can be used to inject or produce any fluid and/or solids from the outside of the filter, as will be explained below. The schematic drawing of FIG. 1 will serve to illustrate the invention disclosed herein. It is intended only as a means of illustration and should not be construed as limiting the scope of the invention in any way. Those skilled in the art will recognize many variations that may be made without departing from the spirit of the disclosed invention. FIG. 1 demonstrates one embodiment utilizing the present invention in a well apparatus. Referring to FIG. 1 there is shown a solids exclusion system in a liner 1 , though, as mentioned the invention can be used in a lined or unlined hole. The liner 1 has perforations 12 to permit fluid flow. Perforations can be made using oil field standard perforation guns, or they can be pre-drilled, or they can be acidized (See, for example, U.S. Pat. No. 5,103,911). The filter 11 of the present invention is situated between the lower assembly 2 and the upper assembly 15 . The upper edge of the filter 11 is received into the upper assembly 15 and the lower edge of the filter 11 is received into the lower assembly 2 . The permeable filter is made of ceramic, metallic or organic material subjected to a sintering or atomic bonding process, as used for the production of nano materials, that provides for any type of porosity required. The upper edge of the filter 11 terminates in a ring 13 which is in contact with memory metal rods 14 which change shape when temperature is applied and which, in turn, are in contact with shut off opening sleeve 17 which has a fishing and/or locator and/or activation recess 16 . In addition, sleeve 17 covers upper circulation port(s) 18 . A fishing and/or locator and/or activation recess is also represented by 19 . In the lower assembly 2 a compression spring 3 holds disc 6 in the position to cover bottom port(s) 5 . The port(s) 5 allow flow from the outside inwards or from the inside outwards if the disc 6 is in the lower position. Disc 6 can be permeable or impermeable. A rod assembly to hold the spring in place is represented by 4 . A fixating plate for the rod assembly 4 is represented by 7 . A wire line lock assembly, which is a standard tool used in the oil industry, is represented by 8 – 10 , i.e. the latches, 8 , the body, 9 , and the fishing and locator groove, 10 . FIG. 2 is an enlarged view, showing detail A, where sealing material is represented by 22 b, and memory metal rods 22 c, used to activate the seals. The numbering of FIG. 2 , corresponds with the numbering of FIG. 1 . The seal 22 consists of a ring 21 a connected to shape memory alloy rods 22 c connected to, ring 22 a. The sealing material 22 b is enclosed by ring 22 a and body 20 . By applying heat to the internal of body 2 , the shape memory alloy will contract and activate the seal. Length of contraction, varies typically between 4% and 8% of the length of the shape memory alloy bars. This allows someone knowledgeable in the art to dimension the seal material, seal length, and shape memory alloy rod length correctly. Another very desirable embodiment of the present invention is that it is possible to circulate flow at the outside of the filter. Again, with reference to FIG. 1 , this is achieved by running a heating coil to the position of the shape memory metal alloy rods 14 . When the shape memory metal alloy rods 14 are heated they contract and shift the sleeve 17 , uncovering the upper port(s) 18 . These ports can be filled with a porous ceramic or metal material. At the same time, or in a separate operation, the bottom port(s) 5 are opened by stinging a pipe, such as coil tubing known from the oil industry, with seals into the body 9 . When pressuring this pipe up the disc 6 will move against the spring 3 and open up bottom port(s) 5 . The opening of the bottom port(s) can also be achieved by pulling the lock assembly comprising 3 , 4 , 6 , 7 , 8 , 9 , and 10 . An alternative method, not shown, is by mechanically pushing the disc 6 against the spring 3 . This allows cleaning of the filter at the outside or removal of any impairment outside the filter by means of circulation in either direction. The cleaning fluid can be any. Suitable fluids can be hydrocarbon-based fluids, acids, scavengers, water-based fluids, gases and/or solvents, or combinations thereof. Circulation can take place through the inner tube, not shown, via bottom port(s) 5 to upper ports 18 after which the fluid is produced back through the annular space between the inner tube, not shown, and the upper assembly 15 . If reverse circulation is required then the mechanical lock open option of disc 6 needs to be used. The port(s) 5 will automatically be closed as soon as the fluid flow through the ports stop and/or the pressure differential over element 6 counteracts the spring force. A wire line tool is run to pull the sleeve 17 up, thereby covering the upper ports 18 . (See WO0138689, incorporated by reference herein in the entirety.) FIG. 1 shows the ports in closed and open position. The third embodiment of the invention, as mentioned above, is that the filter assembly can be used to inject or produce any fluid and/or solids from the outside of the filter 11 by running the inner tube, not shown, and stinging this into the lock assembly. With reference to FIG. 1 , in order to flow back, the total lock assembly comprising 3 , 4 , 6 , 7 , 8 , 9 , and 10 needs to be pulled, the mechanical push open (not shown) variation needs to be installed. Another alternative to this assembly is an oil industry standard wire line set plug. To ensure that the fluids have a defined circulation path seals 22 are placed between the outer tube 1 and the upper 15 and lower 2 assembly ( FIG. 1 ). The solids exclusion system can be kept stationary in the tube 1 ( FIG. 1 ) by the use of oil industry standard tubular and/or formation packers. FIG. 3 shows a sub-section of the screen of which multiples can be connected together with or without intermittent blanks and/or sealing elements. FIG. 3 shows a standard oil field pin 23 with threads 24 and 25 , which is screwed into embodiment 29 locking the screen 27 and filler ring(s) 26 in place. The top section of embodiment 29 shows a standard oil field box connection with threads allowing connection of multiple section and/or standard oil field tubular goods. The holes 28 (equal to item 20 of FIG. 1 ) allow passage of fluids whereby the number, dimension and position of the holes provide a certain spring force which can be controlled in combination with the dimensions of the filler ring(s) 26 and all other relevant dimensions, thus providing enhanced bending and/or axial tensile resistance of the assembly.
Disclosed is a tool having an axial passage, a top and a bottom, and a sidewall portion possessing porosity and permeability properties and constructed of a material having equal or better erosion properties than any substances produced and/or injected into any earth formation, said tool functioning as a filter to permit solids to pass or not pass depending upon their size, characterized in that the porosity and permeability can be programmed to any given value radially and longitudinally, said tool further including a means for circulating from outside, inward or from the inside outward to enable cleaning, wherein optionally said tool can be used in multiples.
4
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to electrical connectors, especially to an electrical connector with an anti-dust device to avoid the poor contact between the movable contact and the fix contact due to dust contamination. [0003] 2. Background of the Invention [0004] With the ever-increasing miniaturization of computer and other electronic equipment, it becomes increasingly difficult to design electrical circuitry for connector thereof. One area of such difficulty is electrical switches or switch assemblies. An electrical switch assembly may be used as a normally open switch with switch contacts designed to be closed upon actuating the switch, or the switch assembly may be a normally closed switch with the contacts designed to be opened when the switch is actuated. [0005] U.S. Pat. No. 4,937,404 issued to Kitagawa on Jun. 26, 1990 discloses an electrical connector comprising an insulative housing and a plurality of contacts, the insulative housing has an observation window, the contacts including signal contacts and switch contacts, the switch contacts including a first movable contact, a second movable contact; a first fix contact and a second fix contact are also included which act in concert with the first movable contact and the second movable contact. The first movable contact has a first elastic portion and a first contact portion extending from the first elastic portion. The first contact portion straps on the first fix contact to form a conductive circuit. [0006] Unfortunately, problems continue to be encountered with the electrical connectors mentioned above. The observation window is helpful to examine the connection between the first contact portion and the first fix contact. However, the dust is easy to get into the observation window and make the first contact portion fail to connect with the first fix contact. Therefore, an improved electrical connector is desired to overcome the disadvantages of the prior arts. SUMMARY OF THE INVENTION [0007] An object, therefore, of the invention is to provide a new and improved electrical connector of the character able to prevent a poor electrical connection between contacts due to the dust contamination. [0008] In order to achieve the objects set forth above, an audio jack for receiving a mating plug according to a preferred embodiment comprises an insulative housing defining a longitudinal plug-insertion hole, a set of contacts assembled on to the insulative housing and including a stationary contact and a movable contact. The stationary contact defines a plate portion. The movable contact has a lateral beam located proximate to the plate portion. An anti-dust dome member is disposed between the stationary contact and the movable contact. The anti-dust dome member includes a first insulative sheet attached onto the plate portion and defining an opening, a middle conductive dome sheet shaped to cover the opening of the first insulative sheet, and a second conductive sheet adhesively disposed on the first insulative sheet to cover the middle conductive dome sheet and to contact the lateral beam of the movable contact, wherein the first insulative sheet is configured to isolate an electrical connection between the second conductive sheet and the stationary contact. The middle conductive dome sheet is constantly actuated to establish an electrical connection between the second conductive sheet and the plate portion of the stationary contact. In this preferred embodiment, due to having the extension of the second conductive sheet from the plate portion to the lateral beam of the movable contact, the electrical connection between the second conductive sheet and the plate portion of the stationary contact will indirectly result in an electrical connection of the stationary contact and the movable contact. Thus, even if dust is deposited on the anti-dust dome member will have no effect on the electrical connection between the stationary contact and the movable contact, because the anti-dust dome member is constantly actuated having no influence of the dust deposition. [0009] Other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0010] The features of this invention which are believed to be novel are set forth with particularity in the appended claims. The invention, together with its objects and the advantages thereof, may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements in the figures and in which: [0011] FIG. 1 is an assembled, perspective view of an electrical connector embodying the concepts of the invention; [0012] FIG. 2 is an exploded, perspective view of the electrical connector shown in FIG. 1 ; [0013] FIG. 3 is another exploded, perspective view of the electrical connector shown in FIG. 1 ; [0014] FIG. 4 is a perspective view showing a stationary contact electrically connected with a movable contact by an anti-dust dome member; and [0015] FIG. 5 is an exploded, perspective view of the anti-dust dome member of the electrical connector shown in FIG. 1 . DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT [0016] Referring to FIG. 1 , an electrical connector 100 includes an insulative housing 4 , a plurality of contacts, a retention device 3 and an anti-dust device or dome member 5 . [0017] Referring to FIG. 2 , contacts includes a signal contact and a switch contact, the signal contact has a first signal contact 21 and a second signal contact 22 ; the switch contact has a first movable contact 23 , a second movable contact 24 , a first fix or stationary contact 25 and a second fix or stationary contact 26 , the first fix contact 25 and second fix contact 26 coordinate with the first movable contact 23 and second movable contact 24 respectively. [0018] Referring to FIGS. 2 and 3 , the first signal contact 21 has a first block portion 210 , a first arm portion 211 and a first soldering portion 212 extending from two ends of the first block portion 210 , the first arm portion 211 extends from the free end and forms a first contact portion 213 , first thorn portions 2100 are formed on two sides of the first block portion 210 , the first contact portion 213 has a dimple 2130 on the surface. [0019] The second signal contact 22 has a second block portion 220 , a second arm portion 221 and a second soldering portion 222 extending from two ends of the second block portion 220 . The second arm portion 221 extends from the free end and forms a second contact portion 223 , the second thorn portions 2200 are formed on two sides of the second block portion 220 . [0020] The first movable contact 23 includes a first retention portion 230 , and a third soldering portion 231 extending from the end of the first retention portion 230 . A first elastic portion 232 and an interfering portion 234 are formed on two sides of the first retention portion 230 respectively. A third contact portion 233 extends from the end of the first elastic portion 232 . [0021] The second movable contact 24 includes a second retention portion 240 and a fourth soldering portion 241 extending from the second retention portion 240 , the second retention portion 240 has a fourth thorn portion 2400 on two sides thereof. A second elastic portion 243 is formed on one side's middle part of the second retention portion 240 . The end of second elastic portion 243 extends and forms a fourth contact portion 244 . [0022] The first fix contact 25 sticks to the first movable contact 23 firmly and includes a first base or a plate portion 250 and a fifth soldering portion 251 , the fifth soldering portion 251 extending from one side of the first base portion 250 . A dust-proof portion 5 of the elastic slice 52 is set at the part where the third contact portion 233 of the first movable contact 23 strap on the first base portion 250 of the first fix contact 25 . The fifth thorn portion 2500 is formed on the first base portion 250 . [0023] The second fix contact 26 includes a second base portion 260 , a sixth contact portion 261 extending from the second base portion 260 and a sixth soldering portion 262 extending from one side of the second base portion 260 . The sixth contact portion 261 sticks to the fourth contact portion 244 of the second movable contact 24 . A sixth thorn portion 2600 is set on the top of the second base portion 260 . [0024] The retention device 3 has a nick which is helpful to the plug's retention after inserting into the electrical connector 100 . [0025] The insulative housing 4 includes a main body 40 ; a joint portion 41 protruding from one side of the main body 40 ; and a patch hole 42 running through the main body 40 and the joint portion 41 . The main body portion 40 includes a top wall 43 , a bottom wall 44 , a first side wall 45 , a second side wall 46 and a back wall 47 , the top of the joint portion 41 has a nick portion 410 which connects the patch hole 42 . [0026] The first side wall 45 and the second side wall 46 have a first opening 450 and a second opening 460 . A lock opening 451 is formed on the first side wall 45 near the back wall 47 ; the back wall 47 has the first groove 471 and the second groove 472 . [0027] The top wall 43 includes a first passageway 431 , a second passageway 432 , a third passageway 433 , a fourth passageway 434 , a fifth passageway 435 , a sixth passageway 436 and a seventh passageway 437 . The third passageway 433 , the fifth passageway 435 and the seventh passageway 437 are set along the side near the first sidewall 45 . The first passageway 431 , the second passageway 432 , the fourth passageway 434 and the sixth passageway are set along the side near the second sidewall 46 . [0028] The bottom wall 44 includes a first groove portion 441 , a second groove portion 442 , a third groove portion 443 , a fourth groove portion 444 , a fifth groove portion 445 , a sixth groove portion 446 and a seven groove portion 447 , which are corresponding to the top wall 43 . [0029] Referring to FIG. 4 , the stable or first fix contact 25 defines the plate portion 250 . The movable contact 23 has a lateral beam 235 located proximate to the plate portion 250 . The anti-dust dome member 5 is attached between the stationary contact 25 and the movable contact 23 . Referring to FIG. 5 , the anti-dust dome member 5 includes a first insulative sheet 53 , a second conductive sheet 51 and a middle conductive dome sheet 52 . The first insulative sheet 53 is attached onto the plate portion 250 and defining an opening 531 . The middle conductive dome sheet 52 is shaped to cover the opening 531 of the first insulative sheet 53 . The second conductive sheet 51 is adhesively disposed on the first insulative sheet 53 to cover the middle conductive dome sheet 52 and to contact the lateral beam 235 of the movable contact 23 , wherein the first insulative sheet 53 is configured to isolate an electrical connection between the second conductive sheet 51 and the stationary contact 25 . As shown in FIGS. 4 and 5 , the middle conductive dome sheet 52 is constantly actuated by an elastic force, which is generated by an elastic arm 233 of an actuating element in its normal state, to enable an electrical contact between the second conductive sheet 51 and the plate portion 250 of the stationary contact 25 via the middle conductive dome sheet 52 on the opening 531 of the first insulative sheet 53 , which indirectly results in an electrical connection of the stationary contact 25 and the movable contact 23 due to having the extension of the second conductive sheet 51 from the plate portion 250 to the lateral beam 235 of the movable contact 23 . In this preferred embodiment, the elastic arm 233 of the actuating element is part of the movable contact 23 . Thus, even if dust is deposited on a joint of the anti-dust dome member 5 and the elastic arm 233 of the actuating element will have no effect on the electrical connection between the stationary contact 25 and the movable contact 23 , which is indirectly and constantly actuated by the elastic force from the actuating element, that is exerted on the an anti-dust dome member 5 . This will avoid the poor electrical connection between the stationary contact 25 and the movable contact 23 due to the influence of dust. In addition, when the elastic arm 233 of the movable contact 23 is at a second state where a complementary plug is inserted into the electrical connector to urge said elastic arm 233 away from said middle conductive dome sheet 52 , the middle conductive dome sheet 52 is no longer actuated to enable the electrical connection between the stationary contact 25 and the movable contact 23 due to having the middle conductive dome sheet 52 left away from the stationary contact 25 and no longer electrically contacting the stationary contact 25 . [0030] It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. [0031] While preferred embodiment in accordance with the present invention have been shown and described, equivalent modifications and changes known to persons skilled in the art according to the spirit of the present invention are considered within the scope of the present invention as defined in the appended claims.
An audio jack comprises a set of contacts including a stationary contact ( 25 ) and a movable contact ( 23 ), and an anti-dust dome member ( 5 ). The anti-dust dome member ( 5 ) includes a conductive sheet ( 51 ) extending from a horizontal plate portion ( 250 ) of the stationary contact ( 25 ) to a lateral beam ( 235 ) of the movable contact ( 23 ), and a middle conductive dome sheet ( 52 ) below the conductive sheet ( 51 ). The conductive dome sheet ( 52 ) is constantly actuated to establish an electrical connection between the stationary contact ( 25 ) and the movable contact ( 23 ). Thus, even if dust is deposited on the anti-dust dome member ( 5 ) will have no effect on the electrical connection as established.
7
BACKGROUND OF THE INVENTION Throughout the ages efforts have been made to reduce the quantities of land that are needed for use as cemetaries required for the disposal of the remains of mortal life. Cremation has been increasing in acceptance and in use, however, the disposal or preservation of the ashes resulting from cremation has long since posed serious problems. Many kinds of containers have been utilized to store the ashen remains, but none has been universally acceptable. Many efforts have been made to devise a storage container that would meet the varied needs and desires of the relatives and friends of deceased parties. FIELD OF THE INVENTION Throughout the ages efforts have been made to provide suitable receptacles for the crematory remains, and literally many shapes and forms of repositories have been devised and used. This invention is directed to the provision of a line of crematory urns that embody a wide range of decorative decor to meet the asthetic desires of relatives and friends of the deceased and which can be used in a wide range of locations to meet the widely divergent needs for crematory urns. By resorting to the use of stained glass, and to the use of new and improved methods of assembling and harmonizing various sections of stained glass a wide range of crematory urns has evolved to meet the widely divergent needs therefor. DESCRIPTION OF THE PRIOR ART Heretofore virtually every conceivable type of container has been used as a crematory urn. The most widely used in recent years has been the glass cannister type which have proven to be very ineffective because they were not dust and moisture proof, and they were objectionable from an aesthetic point of view because they exposed the crematory remains to view to an undesirable degree and they were too drab and suggestive. SUMMARY OF THE INVENTION The primary purpose of this invention is to devise a wide range of crematory urns wherein the beauty of variously colored and shaped sections of stained glass can be combined in unique ways to provide a wide range of crematory urns to meet the needs and desires of a wide range of relatives and friends. An object of this invention resides in the provision of a line of light weight, stained glass crematory urns wherein variously colored segments of glass are combined to provide asethetically acceptable units assembled in accordance with unique methods to provide a wide range of sturdy moisture and dust proof urns wherein the ashen remains are obscured from view. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings wherein similar reference characters refer to similar parts throughout the several views: FIG. 1 is a perspective view of a crematory urn embodying the present invention. FIG. 2 is also a perspective view similar to FIG. 1 taken from a different angle. FIG. 3 is a bottom plan view of the urn illustrated in FIG. 1. FIG. 4 is a sectional view taken substantially on the line 4--4 of FIG. 2 looking in the direction of the arrows. FIG. 5 is a fragmentary sectional view of one of the corners of the embodiment of FIG. 1. FIG. 6 is a sectional view taken substantially on the 6--6 of FIG. 2, looking in the direction of the arrows. DESCRIPTION OF THE PREFERRED EMBODIMENT The cremation urn is formed of a plurality of pieces of stained glass of harmonizing colors selected to provide an appealing combination of colors. The stained glass is generally available in large sheets 4'×4' and it is cut into a desired number of pieces such for example as 16 pieces of varying sizes and colors to be used in the formation of an urn. Referring now to the drawings a typical cremation urn is formed by cutting various pieces of stained glass, such as the segments 10, 12 and 14 which cooperate to form one side panel of the urn. The other side panels can employ similarly sized and shaped segments of the same or harmonizing colors or the other panels can have differently shaped segments and can employ different colors. Another piece of stained glass 16 of approximate size is provided to form the top of the urn. When the pieces of stained glass have been selected to form one of the side panels, a strip of copper foil is applied to all of the edges of the pieces of stained glass 20 completely cover the edge and to extend along the sides of the pieces 20 of the stained glass by a small amount, such for example as approximately 1/8". The pieces of stained glass 20 with the copper foil in place thereon are then laid on a flat surface with a small spacing between them whereupon hot or molten lead is flowed over the joint. The hot lead is attracted by the copper foil so that a straight surface of lead beading following the contours of the copper foil is provided along the junctures of the glass pieces 20. This lead beading is shaped by hand to fill the space between the edges of the pieces of glass and it embodies a slight build-up along the edges which provides a smooth well rounded joint therebetween which lends a pleasing artistic appearance. The lead filling the space between the pieces of stained glass provides in effect a framework 22 formed of the lead which extends along both sides of the glass to securely clamp it in place and to provide a moisture and dust proof joint. When the flat side walls have thus been formed two of them are successively assembled in a jig to join the side walls in the manner heretofore described. It will be noted that a well rounded built up section 22 of lead is provided to form the corners as illustrated in FIGS. 5 and 6. When the sides are thus formed the top 16 is assembled with the sides and it has the copper foil covering the edges and extending down over the sides of the top 16 by an amount ranging for example approximately 1/8". The top of the pieces of stained glass 10, and 14 and any others that extend to the top of the urn are treated with the copper foil. When all is in readiness with the appropriate copper foil in place on the top and on the sides, and the top 16 assembled with the sides forming the upper portion of the urn on a suitable jig, then hot lead is applied to the space between the edges of the glass. The lead flows in seeking contact with the copper foil, and it is hand worked to provide a smooth well rounded layer of lead extending over the edges of all adjacently positioned stained glass pieces. The formed lead increases in thickness between the adjacently positioned pieces of glass to securely hold the stained glass parts in assembled relation. Referring now to FIGS. 3 and 6 it will be noted that a base or bottom 24 preferably about 1/4" in thickness is formed of an acrylic, preferably a black or white or a copper colored acrylic although any color can be used. When the upper portion of the urn is formed, threaded rods 26 as shown in FIG. 6 are soldered or otherwise secured to the seams of each corner. The lower or threaded end 28 of the rods 26 extend below the surface of the urn to project through holes 30 formed in the base or bottom member 24. A ball 32 preferably formed of brass is drilled and threaded to thread onto the threaded ends 28 of the rods 26 projecting through the holes 30 in the base or bottom 24 to hold the base 24 securely on the urn. The base 24 has approximately 1/4" of foam 32 secured on the upper surface of the base 24 to seal the space between the base and the upper portions of the urn secured thereto. The foam material 32 on the upper surface of the base 24 acts as a cushion to prevent any rattling of the cremation remains placed in the urn, and functions to seal the space within the urn. Also a paper board liner 40 is secured in place along the inner edges of the urn to prevent the cremation remains placed in the urn from being visible through the stained glass sides. The cremation urn can of course be formed with varied patterns of stained glass segments 20, for example one side can be a single piece of solid stained glass, or any desired configuration of stained glass segments may be employed. The cremation urns can be of any desired shape, such as rectangular as shown in FIGS. 1 and 2, or they can be hexaginal, square, round or any other desired shape or combination of shapes. One typical size of cremation urn for adult usage is 51/4"×51/4"×71/2" providing an internal capacity of approximately 200 cubic inches. They may range in size for adult usage from approximately 150 cubic inches to approximately 300 cubic inches. For children's size the urns can range from approximately 31/2"×31/2"×41/2" providing an internal capacity of approximately 55 cubic inches. If desired double urns can be provided for husband and wife of a family. These urns, for example are a single unitary structure with a partition to divide the internal space. In use the base 24 is removed by taking off the threaded balls 34 from the rods 26 and removing the base 24. The plastic bag that is provided is opened up and positioned inside the cardboard shield that is provided in the urn. The cremation remains are deposited in the plastic bag and it is then folded over and twist tied. The base 24 is then placed on the four threaded rods 26 which incidentally are color coded since the units are individually made and this renders it easy to be sure that the parts are assembled in the same relation. The washers 36 are then placed on the rods after the base 24 has been assembled and then the internally threaded balls 34 are applied and tightened on the rods 26. The assembled urn can then be inverted and placed in any suitable location such for example as in the niche of a crematory or at any location in the home or elsewhere as desired. If desired the urns can be decorated with any religious or other insignia. Also a nameplate can be affixed to the urns to provide a space for recording names, dates and other significant facts.
This invention utilizes the beauty and durability of stained glass combined with innovative assembly techniques to provide a cremation urn that is pleasing in appearance, light in weight, rugged in construction, and moisture and dust resistant to meet all of the criteria that have been established for cremation urns. On the base a layer of foam on the inside of the urn further seals the urn and prevents rattling of the cremation remains. Also, a paper line prevents the remains from being visible.
1
TECHNICAL FIELD OF THE INVENTION [0001] The technology of the present disclosure relates generally to an autofocus assembly for a camera and, more particularly, to a precision autofocus assembly that establishes two or more subject distance ranges for a camera. DESCRIPTION OF THE RELATED ART [0002] Mobile and/or wireless electronic devices are becoming increasingly popular. For example, mobile telephones, portable media players and portable gaming devices are now in wide-spread use. In addition, the features associated with certain types of electronic devices have become increasingly diverse. For example, many mobile telephones now include cameras. [0003] Due to size and power constraints in a mobile telephone, many camera phones have used a fixed focus camera assembly. But as the resolution of the imaging sensor for these cameras increases (e.g., three to five megapixels or more), it becomes more difficult to achieve acceptable sharpness using a fixed focus arrangement. It has been proposed to add an autofocus system to camera phones to assist in taking sharp photographs at various subject distances, thereby leading to better image quality compared to a fixed focus camera. But adding an autofocus system may increase the cost of the camera system beyond the expectations of many users. [0004] Also, autofocus systems rely on complex and sensitive component assemblies that are not generally practical for camera phones. For example, conventional autofocus systems rely on a mechanical activator that displaces a lens relative to an imaging sensor. The various types of activators that have been used include piezoelectric activators, electromechanical activators implemented with a voice coil acting against a magnet, and stepper motor actuators. Each of these types of activators has advantages and disadvantages. For instance, some actuators are more accurate and/or faster than others, but the better performing actuators are typically more expensive and are harder to control than less accurate and/or slower actuators. The less accurate and/or slower actuators tend to be more economical and easier to manufacture. SUMMARY [0005] To improve focusing of a camera assembly, the present disclosure describes an improved autofocus assembly. The autofocus assembly is particularly well suited for use with camera phones and other miniature cameras. Not only is the disclosed autofocus system cost effective, it achieves a high degree of performance without using a complicated assembly of components. In one embodiment, displacement of a lens assembly is changed by rotating a control member. Positioners (e.g., spherical bearings) may be disposed in through holes in the control member. When the control member is in a first position, the positioners may be received in corresponding receptacles (e.g., apertures or indents) of a displacement member that is located adjacent the control member. In the first position, the lens assembly may have a first optical displacement with respect to an imaging sensor. As the control member is rotated from the first position to a second position with respect to the displacement member, the balls may leave the apertures and ride on a surface of the displacement member. This has the effect of positioning the lens assembly at a second optical displacement with respect to the imaging sensor. The different optical displacements impart different subject distance ranges to the camera system such that actuation between the first and second positions results in changes to the focus of the camera assembly. [0006] A high degree of precision in positioning of the lens assembly with respect to the imaging sensor may be achieved with very little electronic control and, in at least one embodiment, without the use of position sensors and/or a feedback system. In the above-described exemplary embodiment, a high degree of accuracy in the displacement of the lens assembly with respect to the imaging sensor may be readily achieved by controlling the physical thickness of the displacement member, which is a relatively simple task. At the same time, the amount of rotation of the control member need not be precisely controlled since over-rotation of the control member will have little or no impact on the amount of displacement of the lens assembly. Therefore, in the exemplary embodiment, a relatively unsophisticated actuator to effectuate rotation of the control member may be employed. In one embodiment, the actuator may be a shape memory allow (SMA), such as a “muscle wire.” Also, at the time of manufacturing of the camera assembly, little or no calibration and/or adjustment of the autofocus components may be required. In addition, a relatively simple controller may be employed to control the focus of the camera assembly. Furthermore, the autofocus assembly may be bi-stable (e.g., may not move from the first position to the second position or vice versa without actuation) and, therefore, will consume very little or no power between position changes. [0007] According to one aspect of the disclosure, a camera assembly includes an imaging sensor; a lens assembly; and an autofocus assembly that selectively imparts a first displacement between the lens assembly and the imaging sensor and a second displacement between the lens assembly and the imaging sensor, wherein the autofocus assembly includes at least one positioner and an actuator, the actuator configured to move the positioner between a first position in which the positioner contacts a first surface that is in a first plane corresponding to the first displacement and second position in which the positioner contacts a second surface that is in a second plane corresponding to the second displacement, the first and second planes being offset so that a distance between the first displacement and the second displacement directly corresponds to a distance between the first and second planes. [0008] According to one embodiment of the camera assembly, the actuator applies force to a control member that moves the positioner between the first and second positions. [0009] According to one embodiment of the camera assembly, the control member traps the positioner in a receptacle of the control member. [0010] According to one embodiment of the camera assembly, the receptacle of the control member is a through hole. [0011] According to one embodiment of the camera assembly, the first surface is a surface of a displacement member that includes a receptacle into which the positioner is received so that the positioner contacts the second surface. [0012] According to one embodiment of the camera assembly, the receptacle of the displacement member is a through hole. [0013] According to one embodiment of the camera assembly, the second surface is a surface of a camera module housing located adjacent the displacement member, and the camera module housing retains the autofocus assembly and the lens assembly. [0014] According to one embodiment of the camera assembly, the positioner is spherical. [0015] According to one embodiment of the camera assembly, a thickness of the displacement defines the distance between the first displacement and the second displacement. [0016] According to one embodiment of the camera assembly, the positioner further contacts a contact surface of the lens assembly to force the lens assembly between the first and second displacements. [0017] According to one embodiment of the camera assembly, force is applied to the lens assembly to maintain contact between the lens assembly and the positioner. [0018] According to one embodiment of the camera assembly, the force is applied by one or more springs. [0019] According to one embodiment of the camera assembly, the second surface is part of a member other than the displacement member. [0020] According to one embodiment of the camera assembly, force is applied to the lens assembly to maintain contact between the positioner and the first surface when the positioner is in the first position and between the positioner and the second surface when the positioner is in the second position. [0021] According to one embodiment of the camera assembly, the actuator includes a shape memory alloy (SMA) member attached to the control member such that contraction of the SMA member achieves the movement of the control member to move the positioner from the first position to the second position. [0022] According to one embodiment of the camera assembly, the actuator applies counter-force to the control member to return the positioner from the second position to the first position. [0023] According to one embodiment of the camera assembly, the force and the counter-force are applied by contracting different portions of the same SMA member. [0024] According to one embodiment of the camera assembly, the camera assembly is part of a mobile telephone. [0025] These and further features will be apparent with reference to the following description and attached drawings. In the description and drawings, particular embodiments of the invention have been disclosed in detail as being indicative of some of the ways in which the principles of the invention may be employed, but it is understood that the invention is not limited correspondingly in scope. Rather, the invention includes all changes, modifications and equivalents coming within the scope of the claims appended hereto. [0026] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments. [0027] The terms “comprises” and “comprising,” when used in this specification, are taken to specify the presence of stated features, integers, steps or components but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof. BRIEF DESCRIPTION OF THE DRAWINGS [0028] FIGS. 1 and 2 are respectively a front view and a rear view of an exemplary electronic device that includes a camera assembly having an autofocus assembly; [0029] FIG. 3 is an exploded view of an exemplary autofocus assembly for the camera assembly; [0030] FIG. 4 is a perspective view of an assembled control member and an actuator member for the autofocus assembly of FIG. 3 ; [0031] FIG. 5 is a schematic block diagram of the electronic device of FIGS. 1 and 2 ; and [0032] FIG. 6 is a schematic diagram of a communications system in which the electronic device of FIGS. 1 and 2 may operate. DETAILED DESCRIPTION OF EMBODIMENTS [0033] Embodiments will now be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. It will be understood that the figures are not necessarily to scale. [0034] Described below in conjunction with the appended figures are various embodiments of an improved autofocus assembly. In the illustrated embodiments, the autofocus assembly has two positions that correspond to two subject distance ranges, but other embodiments of the autofocus assembly may have more than two subject distance ranges. The disclosed autofocus assembly differs from many conventional high performance autofocus assemblies that typically position a lens among twenty to thirty discrete positions. While the conventional high performance autofocus assemblies may facilitate taking sharp pictures at subject distances from about ten centimeters to infinity, the disclosed approach may assist in taking photographs that are acceptable to most camera phone users. [0035] A fixed focus solution, on the other hand, has a fixed subject distance. In a fixed focus system, the camera relies on a depth of field of the lens to obtain a fairly large subject distance range. The exact range for a particular fixed focus camera will depend on the lens focal length, the aperture, the pixel count and the optical format of the imaging sensor. As the pixel count of the sensor increases, the depth of field becomes shallower (assuming the other parameters stay the same). [0036] A fixed focus camera is usually focused at its hyperfocal distance (LH), meaning that an acceptable image may be captured at subject distances from a near distance (L NEAR ) of about half the hyperfocal distance (LH divided by 2) to a far distance (L FAR ) equaling infinity. The hyperfocal distance may be calculated using equation 1 where f is the focal length of the lens assembly, N is the aperture (F-number) and C is the blur circle (largest permissible circle for a light bundle incident on the imaging sensor, also known as the largest permissible circle of confusion). [0000] Hyperfocal   Distance   L H = f 2 NC Eq .  1 [0037] As an example, a camera may have an imaging sensor with three million pixels and a pixel pitch of 1.75 microns, and a lens with a focal length of 3.7 millimeters to achieve a horizontal field of view of about fifty two degrees. If the blur circle is double the pixel pitch, the blur circle for the camera would be about 3.5 microns. Solving equation 1 would determine that the hyperfocal distance is about 1.4 meters. Therefore, the near focus distance (L NEAR ) of this exemplary camera would be about seventy centimeters. [0038] If the user is interested in taking pictures of objects closer than seventy centimeters, blurry photographs would likely result. The autofocus solution described herein lowers the available near distance. In one embodiment, the disclosed autofocus solution adds a second focus setting. Following the foregoing example for the three megapixel camera, the first focus setting may be about 1.4 meters to provide a first subject range of about seventy centimeters to infinity. The second focus setting may be set to about forty seven centimeters, or about one third of the exemplary hyperfocal distance. In the second setting, the near distance would be about thirty five centimeters, or about one quarter the hyperfocal distance, and the far distance would be about seventy centimeters. Therefore, by switching between the first setting and the second setting in accordance with the proximity of an object to be photographed with the camera, an effective focus range of about thirty five centimeters to infinity may be established with just the two lens positions. In the example, the displacement of the lens assembly between the first focus setting and the second focus setting is about twenty microns. [0039] The autofocus assembly will be primarily described in the context of positioning a lens assembly for a digital camera (e.g., a digital still camera and/or a digital video camera) for a mobile telephone. It will be appreciated that the autofocus assembly may be used in other operational contexts such as, but not limited to, a dedicated camera, another type of electronic device that has a camera (e.g., a personal digital assistant (PDA), a media player, a gaming device, a “web” camera, a computer, etc.), a projector, and so forth. It is further noted that the interchangeable terms “electronic equipment” and “electronic device” include portable radio communication equipment. The term “portable radio communication equipment,” which hereinafter is referred to as a “mobile radio terminal,” includes all equipment such as mobile telephones, pagers, communicators, electronic organizers, PDAs, smartphones, portable communication apparatus or the like. [0040] Referring initially to FIGS. 1 and 2 , an electronic device 10 is shown. The illustrated electronic device 10 is a mobile telephone. The electronic device 10 includes a camera assembly 12 for taking digital still pictures and/or digital video clips. Therefore, it is highlighted that the electronic device 10 need not be a mobile telephone, but could be a dedicated camera or some other device as indicated above. [0041] With additional reference to FIG. 3 , the electronic device 10 may include an autofocus assembly 14 . In the illustrated embodiment, the autofocus assembly 14 moves a lens assembly 16 between a first position and a second position. In the first position, the lens assembly 16 has a first displacement with respect to an imaging sensor 18 and, in the second position, the lens assembly 16 has a second displacement with respect to the imaging sensor 18 . The first and second positions respectively impart a first focus range and a second focus range to the camera assembly 12 . [0042] The autofocus assembly 14 , the lens assembly 16 and the imaging sensor 18 may be collectively assembled to form a camera module 20 that may be mounted within a housing 22 of the electronic device 10 . The lens assembly 16 may include one or more lenses 24 that are retained by a lens retainer 26 . The imaging sensor 18 captures images of a scene contained within a field of view of the camera assembly 12 while the lens assembly 16 focuses light from the field of view onto the imaging sensor 18 . A window 28 may be present over an opening in the housing 22 to serve as a protective cover for the camera module 20 . The window 28 may also function as a lens and/or a filter. In another embodiment, the window 28 may be omitted or formed as part of the lens assembly 16 . The camera module 20 may include other optical components, such as filters, prisms, mirrors, optical zooming mechanics, a lens or lenses that remain stationary relative to the imaging sensor 18 , etc. [0043] It will be appreciated that the camera assembly 12 may include additional components that may form part of the camera module 20 or that may be retained by the electronic device 10 separately from the camera module 20 . For instance, the camera assembly 12 may include an electronic controller (not illustrated) that controls operation of the camera module 20 and other camera assembly 12 operations. Other components of the camera assembly 12 include, for example, a flash 30 , a light meter 32 , a display 34 for functioning as an electronic viewfinder and as part of an interactive a user interface, a keypad 36 and/or buttons 38 for accepting user inputs, an optical viewfinder (not shown), and any other components commonly associated with cameras. [0044] Referring now to FIGS. 3 and 4 , details of the illustrated embodiment of the autofocus assembly 14 will be described. The autofocus assembly 14 of the illustrated embodiment is configured to impart movement of the lens assembly 16 . It will be appreciated that the operative principles of the autofocus assembly 14 instead may be applied to impart movement to the imaging sensor 18 , or both the imaging sensor 18 and the lens assembly 16 . [0045] The autofocus assembly 14 may include a stack of components, including a platform 40 , a displacement member 42 , a control member 44 , a plurality of positioners 46 , and a spring 48 . The lens assembly 16 may be located between the spring 48 and the control member 44 . The platform 40 may form part of a housing for the camera module 20 . [0046] Using directional and relational terms that correspond to the illustrated vertical arrangement of components, the interaction of the components will be described. It will be appreciated that different directional and relational terms may be used depending on the orientation of the components, changes in the order of components, and/or the addition and/or subtraction of components. [0047] As illustrated, many of the components may include a central through hole to create an optical pathway for light to travel from an opening in the housing 22 (which may be covered by the window 28 ), through the lens assembly 16 and onto an operative portion of the imaging sensor 18 . [0048] An upper end of the spring 48 may contact a lower surface of the housing 22 . In other embodiments, the upper end of the spring 48 may contact another surface, such as a dedicated housing member (not illustrated) for the camera module 20 . A lower end of the spring 48 may contact an upper surface of the lens retainer 26 . The lens retainer 26 may have a stepped radius along the longitudinal axis of the lens retainer. The stepped radius may be arranged such that the upper portion of the lens retainer 26 includes a flange 50 that has a lower surface that serves as a contact surface 51 for the positioners 46 . The lower portion of the lens retainer 26 may fit in the central through hole of one or more of the control member 44 , the displacement member 42 and the platform 40 . Also, while the flange 50 , the control member 44 and the displacement member 42 are shown and described as being annular in nature (e.g., round), these components may have other geometries. Also, other structures that are shown and/or described as being circular and/or spherical may have other geometries. [0049] When the autofocus assembly 14 is assembled, each positioner 46 may fit within a receptacle of the control member 44 so that the positioners 46 are laterally trapped by the control member 44 . In the illustrated embodiment, each positioner 46 fits within a corresponding through hole 52 of the control member 44 such that the control member 44 surrounds a vertically central portion of the positions 46 . In this manner, the positioners 46 are laterally trapped by the control member 44 and rotation of the control member 44 causes corresponding circumferential movement of the positioners 46 about a longitudinal axis of the autofocus assembly 14 . The upper portion of the positioners 46 may contact the contact surface 51 of the flange 50 . The control member 44 may include a radially projecting lever 54 . Applying circumferentially directed force to the lever 54 may result in rotation of the control member 44 and corresponding movement of the positioners 46 . [0050] The positioners 46 of the illustrated embodiment are spheres. For instance, the positioners 46 may be ball bearings. In another embodiment, the positioners 46 may be located in and trapped by recesses in a lower surface of the control member 44 . Alternatively, the positioners 46 may be bumps or detents that are formed on or integral with a lower surface of the control member 44 . In these embodiments the positioners 46 do not contact the contact surface 51 . Instead, an upper surface of the control member 44 may contact the contract surface 51 . Also, even when the positioners 46 extend through an upper surface of the control member 44 , the upper surface of the control member 44 may contact the contact surface 51 in one or both of the positions of the autofocus assembly 14 . [0051] The control member 44 may rest over (and possibly contact) the displacement member 42 , which may have receptacles in which lower portions of the positioners 46 may be received when the receptacles (e.g., holes 52 ) of the control member are vertically aligned with the receptacles of the displacement member 42 . In the illustrated embodiment, the receptacles of the displacement member 42 are through holes 56 . In this embodiment, when the autofocus assembly 14 is in the second position so that the displacement of the lens assembly 16 is closer to the imaging sensor 18 relative to the first position, the through holes 52 of the control member 44 and the through holes 56 of the displacement member 42 may be vertically aligned. In this position, the lower portions of the positioners 46 may contact an upper surface of the platform 40 . Therefore, the distance between the upper surface of the platform 40 and contact surface 51 will be about the diameter of the positioners 46 . [0052] Application of circumferentially directed force on the lever 54 may urge the control member 44 in a corresponding rotational direction. Under this force, the positioners 46 may ride up and out of the through holes 56 , and onto the upper surface of the displacement member 42 to achieve the first position of the autofocus assembly 14 . Also, the lens assembly 16 will be forced upward against the spring 48 , which may compress in reaction to the upward force. In this position, the distance between the upper surface upper surface of the platform 40 and contact surface 51 will be about the diameter of the positioners 46 plus the thickness of the displacement member 42 . The autofocus assembly 14 may be moved from the first position back to the second position by applying force to the lever 54 to urge the control member 44 in a direction to achieve alignment of the through holes 52 and the through holes 56 . While the illustrated spring 48 is shown as a coil spring, one or more leaf springs or other resilient members may be positioned to apply downward pressure on the lens assembly 16 . Also, one or more coil springs may be positioned between the platform 40 and the lens assembly 16 to pull the lens assembly 16 downward. [0053] It will be appreciated that the difference in the displacement of the lens assembly 16 with respect to the imaging sensor 18 will change by the thickness of the displacement member 42 when the autofocus assembly 14 moves between the first and second positions. The thickness of the displacement member 42 and the thickness of the positioners 46 may be controlled so that when the autofocus assembly 14 is in the first position, objects in a first focus range of the camera assembly 12 may be satisfactorily imaged. As indicated above, the first focus range may be about half the hyperfocal distance to infinity. Also, the thickness of the displacement member 42 and the positioners 46 may be controlled so that when the autofocus assembly 14 is in the second position, the second focus range may be about a quarter of the hyperfocal distance to about half of the hyperfocal distance. It will be appreciated that other thicknesses can be used to achieve other focus ranges. Following the above-described example of the three megapixel camera, the thickness of the displacement member 42 may be about twenty microns to achieve a first focus range of about seventy centimeters to infinity and a second focus range of about thirty five centimeters to about seventy centimeters. [0054] To assist in accurately controlling the displacement of the lens assembly 16 , the applicable upper and lower surfaces of the lens assembly 16 , the control member 44 , the displacement member 42 and the platform 40 may be in generally parallel planes. [0055] In another embodiment, the displacement member 42 may be omitted and recesses with controlled depths may be formed in the upper surface of the platform 40 to receive the positioners 46 when the autofocus assembly 14 is in the second position. In another embodiment, the platform may have raised steps (e.g., rectangular blocks). The positioners 46 may rest on the platform 40 in areas between the steps when the autofocus assembly 14 is in the second position and the positioners 46 may rest on the steps when the control member 44 is rotated so that the autofocus assembly 14 is in the first position. In these embodiments, the platform 40 may be considered a displacement member. [0056] In another embodiment, the control member 44 may be omitted in favor of pockets that trap the positioners 46 in the contact surface 51 of the lens assembly 16 . In this embodiment, displacement of the lens assembly 16 may be achieved by rotation of the lens assembly 16 or the displacement member 42 . Also, in this embodiment, the lens retainer 26 may be considered a control member. [0057] In still another embodiment, the control member 44 may be omitted in favor of positioners 46 that are formed as part of the lens retainer 26 . For instance, the positioners 46 may take the form of detents that are formed on the under side of the flange 50 . The detents may be, for example, polygons with beveled or rounded corners. Also, the displacement member 42 may be omitted in favor of receptacles formed in the platform 40 . The receptacles may have a cross-sectional profile the approximates a cross-sectional profile of the positioners 46 . For instance, the receptacles may be indents that have bottom surfaces that contact bottom surfaces of the positioners 46 when the autofocus assembly 14 is in the second position. When the autofocus assembly 14 is moved to the first position, the detents may slide out of the indents so that the bottom surfaces of the detents rest on the upper surface of the platform 40 . In this manner, the vertical distance between the bottom of the indents and the surface of the platform 40 may control the displacement of the lens assembly 16 . To facilitate movement from the second position to the first position and vice versa, the edges of the detents and the sidewalls of the indents may be made at corresponding angles (e.g., the sidewalls of the indents may be angled to act as a ramp for the detents). In this embodiment, the platform 40 may be considered a displacement member and the lens retainer 26 may be considered a control member. In a similar embodiment, the detents may be placed on the platform 40 and the indents may be formed in the lens retainer 26 . [0058] In still another embodiment, a spacer member may be positioned between the displacement member 42 and the platform 40 and/or a spacer member may be positioned between the upper portion of the positioners 46 and the contact surface 51 . The spacer member(s) may be used to assist in establishing a desired optical displacement between the lens assembly 16 and the imaging sensor 18 . Even with the presence of a spacer member(s), the optical displacement between the lens assembly 16 and the imaging sensor 18 may be controlled by the thickness of the displacement member 42 . [0059] In yet another embodiment, the components may be placed in a different order. For instance, the spring 48 may be positioned under the contact surface 51 and the control member 44 , the displacement member 42 and the positioners 46 may be located above the lens assembly 16 . [0060] In another embodiment, the autofocus assembly 14 may have more than two positions. For instance, the displacement member 42 may not have an upper surface and a lower surface that are in parallel planes. Rather, the upper surface of the displacement member 42 may be stepped, sloped, beveled, have cam surfaces, have recesses of varying depths, etc. Rotation of the control member 44 may be controlled to bring the positioner 46 into alignment with various points of the displacement member 42 so as to effectuate a corresponding number of displacements of the lens assembly 16 . [0061] The general operation of the autofocus assembly 14 for the illustrated embodiment may be summarized as follows. When the components are aligned so that the positioners 46 pass through the through holes 52 in the control member 44 and the through holes 56 the displacement member 42 , the spring 48 pushes the lens assembly 16 to establish contact between the lens assembly 16 and the positioners 46 and to establish contact between the positioners 46 and the platform 40 . As the control member 44 is rotated, the positioners 46 are forced to leave the through holes 56 in the displacement member 42 and climb upward and on to the upper surface of the displacement member 42 . In the rotated configuration, the spring 48 pushes the lens assembly 16 downward to establish contact between the lens assembly 16 and the positioners 46 and to establish contact between the positioners 46 and the displacement member 42 . The upward travel of the positioners 46 also results in upward movement of the lens assembly 16 . In this manner, the distance between the lens assembly 16 and the platform 40 is elevated an amount equal to (or a function of) the thickness of the displacement member 42 . Thus, the displacement of the lens assembly 16 with respect to the imaging sensor 18 also is changed an amount commensurate with the thickness of the displacement member 42 . Rotation of the control member 44 to re-establish alignment of the through holes 52 and 56 allows the positioners 46 to leave the surface of the displacement member 42 and, under the force of the spring 48 , move into the holes 56 . In this manner, the positioners 46 and the lens assembly 16 move optically closer to the imaging sensor 18 a distance that is commensurate with the thickness of the displacement member 42 . [0062] As will be appreciated, the autofocus assembly 14 provides very accurate displacement of the lens assembly 16 that is not dependent on the accuracy of the amount of rotation of the control member 44 . So long as the control member 44 is rotated a threshold amount, displacement of the lens assembly 16 may be achieved. The threshold amount may be, for example, at least the radius of the positioners 46 , but is preferably a little more. An appropriate range for the threshold amount in an exemplary embodiment may be about three quarters of the diameter of the positioners 46 to about twice the diameter of the positioners 46 . [0063] The control member 44 may be rotated by an actuator 58 . As indicated, the precision of actuator 58 need not be high to achieve a high degree of precision in the displacement of the lens assembly 16 . Exemplary actuators 58 may include one or more motors, one or more electromagnetic actuators, and one or more piezoelectric actuators. [0064] As shown in the illustrated embodiment, the actuator 58 may include a member 60 that is made from a shape memory alloy (SMA). In the illustrated embodiment, the member 60 is a wire SMA member, which is commonly known as a “muscle wire.” Wire SMA members exhibit the property of shrinking in length when heated to a suitable temperature, which is typically about eighty degrees Celsius to about ninety degrees Celsius. For instance, many SMA wires will contract in length about three percent to about eight percent when heated to a temperature of about ninety degrees Celsius. Heating of the wire may be achieved by passing a current through the wire to create resistive heating. When the wire cools by a few degrees it may soften and may be expanded to its original length by applying a relatively weak mechanical force. Suitable wire SMA members are sold by Nitinol Devices and Components of Fremont, Calif., USA, and under the designation FLEXINOL by Dynalloy, Inc. of Costa Mesa, Calif., USA, as well as other manufacturers and vendors. [0065] With continued reference to FIGS. 3 and 4 , FIG. 3 shows the member 60 assembled with retaining components of the camera module 20 and FIG. 4 shows the member 60 assembled with the control member 44 . When the camera assembly 12 is fully assembled, the member 60 will be assembled with both the retaining components of the camera module 20 and the control member 44 . [0066] The member 60 may have a first end that is mechanically secured and electrically connected to a first electrical terminal 62 (shown schematically in FIG. 4 as a node). A second end of the member 60 may be mechanically secured and electrically connected to a second electrical terminal 64 (shown schematically in FIG. 4 as a node). A point of the member 60 between the first and second ends of the member 60 may be in at least electrical connection with a third terminal 66 . In the illustrated embodiment, the member 60 is mechanically and electrically connected to the third terminal 66 at about a midpoint between the first and second ends. In an alternative embodiment, a first SMA member may be connected between the first terminal 62 and the third terminal 66 and a second SMA member may be connected between the second terminal 64 and the third terminal 66 (or a fourth terminal). [0067] Connected to the platform 40 or integrally formed with the platform 40 may be posts that are used to support and guide the member 60 . The posts may be non-conductive so as not interfere with current that is passed through the member 60 . In one embodiment, the posts may be replaced by sidewalls of a housing for the camera module 20 . [0068] In the illustrated embodiment, the terminals 62 , 64 and 66 are centrally mounted to the platform 40 along a rear edge of the platform 40 . Proceeding from the first terminal, the member 60 may be threaded through a first post 68 that is located at the rear, left-hand corner of the platform 40 and then through a second post 70 that is located at the front, left-hand corner of the platform 40 . Then, the member 60 is threaded vertically through a first hole 72 in the lever 54 and returns to the third terminal 66 through the second post 70 and the first post 68 . Proceeding from the third terminal 66 , the member 60 may be threaded through a third post 74 that is located at the rear, right-hand corner of the platform 40 and then through a fourth post 76 that is located at the front, right-hand corner of the platform 40 . Then, the member 60 is threaded vertically through a second hole 78 in the lever 54 and returns to the second terminal 64 through the fourth post 76 and the third post 74 . [0069] The third terminal 66 may function as a common ground for a first portion 80 of the member 60 that is connected between the first terminal 62 and the third terminal 66 and for a second portion 82 of the member 60 that is connected between the second terminal 64 and the third terminal 66 . When a control signal is applied to the first portion 80 (e.g., by passing current between the first terminal 62 and the third terminal 66 and through the first portion 80 ), the control member 44 may be rotated in a clockwise direction by contraction of the first portion 80 of the member 60 . Similarly, when a control signal is applied to the second portion 82 (e.g., by passing current between the second terminal 64 and the third terminal 66 and through the second portion 82 ), the control member 44 may be rotated in a counter-clockwise direction by contraction of the second portion 82 of the member 60 . In one embodiment, the control member 44 may be rotated clockwise to dislodge the positioners 46 from the holes 56 in the displacement member 42 and may be rotated counter-clockwise to return the positioners 46 to the holes 56 . In another embodiment, the control member 44 may be rotated counter-clockwise to dislodge the positioners 46 from the holes 56 in the displacement member 42 and may be rotated clockwise to return the positioners 46 to the holes 56 . Directing the member 60 around the perimeter of the control member 44 may provide enough length to the member 60 so that the member 60 may be contracted enough to result in sufficient rotational movement of the control member 44 . [0070] In one embodiment, the coil spring 48 of the illustrated embodiment may be replaced by clips, leaf springs, resilient members or elastic members that are retained by the posts. For instance, a first resilient strap may be retained by two adjacent posts (e.g., posts 68 and 70 ) and a second resilient strap may be retained by another pair of adjacent posts (e.g., posts 74 and 76 ). The straps may engage an upper surface of the lens retainer 26 to apply downward pressure to the lens assembly 16 . In another embodiment, downward force on the lens assembly may be indirectly exerted on the lens assembly 16 . For instance, force may be exerted on a supplemental ring that, in turn, acts upon the lens assembly 16 . [0071] As indicated, the illustrated electronic device 10 shown in FIGS. 1 and 2 is a mobile telephone. Features of the electronic device 10 , when implemented as a mobile telephone, will be described with additional reference to FIG. 5 . The electronic device 10 is shown as having a “brick” or “block” form factor housing, but it will be appreciated that other housing types may be utilized, such as a “flip-open” form factor (e.g., a “clamshell” housing) or a slide-type form factor (e.g., a “slider” housing). [0072] As indicated, the electronic device 10 may include the display 34 . The display 34 displays information to a user such as operating state, time, telephone numbers, contact information, various menus, etc., that enable the user to utilize the various features of the electronic device 10 . The display 34 also may be used to visually display content received by the electronic device 10 and/or retrieved from a memory 84 ( FIG. 5 ) of the electronic device 10 . The display 34 may be used to present images, video and other graphics to the user, such as photographs, mobile television content and video associated with games. [0073] The keypad 36 and/or buttons 38 may provide for a variety of user input operations. For example, the keypad 36 may include alphanumeric keys for allowing entry of alphanumeric information such as telephone numbers, phone lists, contact information, notes, text, etc. In addition, the keypad 36 and/or buttons 38 may include special function keys such as a “call send” key for initiating or answering a call, and a “call end” key for ending or “hanging up” a call. Special function keys also may include menu navigation and select keys to facilitate navigating through a menu displayed on the display 34 . For instance, a pointing device and/or navigation keys may be present to accept directional inputs from a user. Special function keys may include audiovisual content playback keys to start, stop and pause playback, skip or repeat tracks, and so forth. Other keys associated with the mobile telephone may include a volume key, an audio mute key, an on/off power key, a web browser launch key, a camera key, etc. Keys or key-like functionality also may be embodied as a touch screen associated with the display 34 . Also, the display 34 and keypad 36 and/or buttons 38 may be used in conjunction with one another to implement soft key functionality. [0074] The electronic device 10 may include call circuitry that enables the electronic device 10 to establish a call and/or exchange signals with a called/calling device, which typically may be another mobile telephone or landline telephone. However, the called/calling device need not be another telephone, but may be some other device such as an Internet web server, content providing server, etc. Calls may take any suitable form. For example, the call could be a conventional call that is established over a cellular circuit-switched network or a voice over Internet Protocol (VoIP) call that is established over a packet-switched capability of a cellular network or over an alternative packet-switched network, such as WiFi (e.g., a network based on the IEEE 802.11 standard), WiMax (e.g., a network based on the IEEE 802.16 standard), etc. Another example includes a video enabled call that is established over a cellular or alternative network. [0075] The electronic device 10 may be configured to transmit, receive and/or process data, such as text messages, instant messages, electronic mail messages, multimedia messages, image files, video files, audio files, ring tones, streaming audio, streaming video, data feeds (including podcasts and really simple syndication (RSS) data feeds), and so forth. It is noted that a text message is commonly referred to by some as “an SMS,” which stands for simple message service. SMS is a typical standard for exchanging text messages. Similarly, a multimedia message is commonly referred to by some as “an MMS,” which stands for multimedia message service. MMS is a typical standard for exchanging multimedia messages. Processing data may include storing the data in the memory 84 , executing applications to allow user interaction with the data, displaying video and/or image content associated with the data, outputting audio sounds associated with the data, and so forth. [0076] The electronic device 10 may include a primary control circuit 86 that is configured to carry out overall control of the functions and operations of the electronic device 10 . The control circuit 86 may be responsible for controlling actuation of the autofocus assembly 14 . Alternatively, control of the autofocus assembly 14 may be handled by a separate controller (not shown) of the camera assembly 12 . The control circuit 86 may include a processing device 88 , such as a central processing unit (CPU), microcontroller or microprocessor. The processing device 88 executes code stored in a memory (not shown) within the control circuit 86 and/or in a separate memory, such as the memory 84 , in order to carry out operation of the electronic device 10 . [0077] Among other data storage responsibilities, the memory 84 may be used to store images captured by the camera assembly 12 . Alternatively, the images may be stored in a separate memory. The memory 84 may be, for example, one or more of a buffer, a flash memory, a hard drive, a removable media, a volatile memory, a non-volatile memory, a random access memory (RAM), or other suitable device. In a typical arrangement, the memory 84 may include a non-volatile memory (e.g., a NAND or NOR architecture flash memory) for long term data storage and a volatile memory that functions as system memory for the control circuit 86 . The volatile memory may be a RAM implemented with synchronous dynamic random access memory (SDRAM), for example. The memory 84 may exchange data with the control circuit 86 over a data bus. Accompanying control lines and an address bus between the memory 84 and the control circuit 86 also may be present. [0078] The processing device 88 may execute code that implements the various functions of the electronic device 10 . It will be apparent to a person having ordinary skill in the art of computer programming, and specifically in application programming for mobile telephones or other electronic devices, how to program a electronic device 10 to operate and carry out various logical functions. [0079] Continuing to refer to FIGS. 1 , 2 , and 5 , the electronic device 10 includes an antenna 90 coupled to a radio circuit 92 . The radio circuit 92 includes a radio frequency transmitter and receiver for transmitting and receiving signals via the antenna 90 . The radio circuit 92 may be configured to operate in a mobile communications system and may be used to send and receive data and/or audiovisual content. Receiver types for interaction with a mobile radio network and/or broadcasting network include, but are not limited to, global system for mobile communications (GSM), code division multiple access (CDMA), wideband CDMA (WCDMA), general packet radio service (GPRS), WiFi, WiMax, digital video broadcasting-handheld (DVB-H), integrated services digital broadcasting (ISDB), etc., as well as advanced versions of these standards. It will be appreciated that the antenna 90 and the radio circuit 92 may represent one or more than one radio transceivers. [0080] The electronic device 10 further includes a sound signal processing circuit 94 for processing audio signals transmitted by and received from the radio circuit 92 . Coupled to the sound processing circuit 94 are a speaker 96 and a microphone 98 that enable a user to listen and speak via the electronic device 10 as is conventional. The radio circuit 92 and sound processing circuit 94 are each coupled to the control circuit 86 so as to carry out overall operation. Audio data may be passed from the control circuit 86 to the sound signal processing circuit 94 for playback to the user. The audio data may include, for example, audio data from an audio file stored by the memory 84 and retrieved by the control circuit 86 , or received audio data such as in the form of streaming audio data from a mobile radio service. The sound processing circuit 94 may include any appropriate buffers, decoders, amplifiers and so forth. [0081] The display 34 may be coupled to the control circuit 86 by a video processing circuit 100 that converts video data to a video signal used to drive the display 34 . The video processing circuit 100 may include any appropriate buffers, decoders, video data processors and so forth. The video data may be generated by the control circuit 86 , retrieved from a video file that is stored in the memory 84 , derived from an incoming video data stream that is received by the radio circuit 92 or obtained by any other suitable method. [0082] The electronic device 10 may further include one or more I/O interface(s) 102 . The I/O interface(s) 102 may be in the form of typical mobile telephone I/O interfaces and may include one or more electrical connectors. As is typical, the I/O interface(s) 102 may be used to couple the electronic device 10 to a battery charger to charge a battery of a power supply unit (PSU) 104 within the electronic device 10 . In addition, or in the alternative, the I/O interface(s) 102 may serve to connect the electronic device 10 to a headset assembly (e.g., a personal handsfree (PHF) device) that has a wired interface with the electronic device 10 . Further, the I/O interface(s) 102 may serve to connect the electronic device 10 to a personal computer or other device via a data cable for the exchange of data. The electronic device 10 may receive operating power via the I/O interface(s) 102 when connected to a vehicle power adapter or an electricity outlet power adapter. The PSU 104 may supply power to operate the electronic device 10 in the absence of an external power source. [0083] The electronic device 10 also may include a system clock 106 for clocking the various components of the electronic device 10 , such as the control circuit 86 and the memory 84 . [0084] The electronic device 10 also may include a position data receiver 108 , such as a global positioning system (GPS) receiver, Galileo satellite system receiver or the like. The position data receiver 108 may be involved in determining the location of the electronic device 10 . [0085] The electronic device 10 also may include a local wireless interface 110 , such as an infrared transceiver and/or an RF interface (e.g., a Bluetooth interface), for establishing communication with an accessory, another mobile radio terminal, a computer or another device. For example, the local wireless interface 110 may operatively couple the electronic device 10 to a headset assembly (e.g., a PHF device) in an embodiment where the headset assembly has a corresponding wireless interface. [0086] With additional reference to FIG. 6 , the electronic device 10 may be configured to operate as part of a communications system 112 . The system 112 may include a communications network 114 having a server 116 (or servers) for managing calls placed by and destined to the electronic device 10 , transmitting data to the electronic device 10 and carrying out any other support functions. The server 116 communicates with the electronic device 10 via a transmission medium. The transmission medium may be any appropriate device or assembly, including, for example, a communications tower (e.g., a cell tower), another mobile telephone, a wireless access point, a satellite, etc. Portions of the network may include wireless transmission pathways. The network 114 may support the communications activity of multiple electronic devices 10 and other types of end user devices. As will be appreciated, the server 116 may be configured as a typical computer system used to carry out server functions and may include a processor configured to execute software containing logical instructions that embody the functions of the server 116 and a memory to store such software. [0087] Although certain embodiments have been shown and described, it is understood that equivalents and modifications falling within the scope of the appended claims will occur to others who are skilled in the art upon the reading and understanding of this specification.
A camera assembly may include an autofocus assembly that selectively imparts a first displacement between a lens assembly and an imaging sensor and a second displacement between the lens assembly and the imaging sensor. The autofocus assembly includes at least one positioner and an actuator. The actuator is configured to move the positioner between a first position in which the positioner contacts a first surface that is in a first plane corresponding to the first displacement and second position in which the positioner contacts a second surface that is in a second plane corresponding to the second displacement. The first and second planes may be offset so that a distance between the first displacement and the second displacement directly corresponds to a distance between the first and second planes.
6
CROSS-REFERENCE TO RELATED APPLICATION [0001] The present application is a non-provisional of U.S. Ser. No. 61/778,814, filed Mar. 13, 2013, incorporated by reference in its entirety for all purposes. REFERENCE TO A SEQUENCE LISTING IN COMPUTER READABLE FORM [0002] The application includes sequences in txt file 439616SEQLIST.txt created Feb. 21, 2014, and 1 kbyte in size, which is incorporated by reference. FIELD [0003] Genetically modified non-human animals that have a mutant allele of an Acvr1 gene; nucleic acid constructs that comprise conditional mutants of an Acvr1 gene; non-human animals that exhibit a phenotypical feature of fibrodysplasia ossificans progressiva (FOP). Genetically modified mice that exhibit ectopic bone formation. Non-human animals containing conditional mutant ACRV1 alleles that are expressed ex utero but not in utero. BACKGROUND [0004] Acrv1 is a type I receptor for bone morphogenic proteins (BMPs). Certain mutations in the human Acvr1 gene, including mutations that give rise to the amino acid modification R206H mutation, are strongly associated with the disease fibrodysplasia ossificans progressiva (FOP) (see, e.g., US Pat. Appl. Publ. No. 2009/0253132; see also, Pignolo, R. J. (2011) Fibrodysplasia Ossificans Progressiva: Clinical and Genetic Aspects, Orphanet Journal of Rare Diseases, 6:80,1-6). The R206H mutation, among others, is believed to increase sensitivity of the receptor to activation and render it more resistant to silencing. Chimeric mice that bear an R206H mutation in Acvr1 develop an FOP-like phenotype (see, e.g., Chakkalakal et al. (2012) An Acvr1 R206H knock-in mouse has fibrodysplasia ossificans progressiva, J. Bone and Mineral Res. 27:1746-1756). [0005] Certain mutations in the Acvr1, e.g., those resulting in an R206H Acvr1 protein mutation, are perinatal lethal in mice. Where a mutation is perinatal lethal, it is not possible to pass a knock-in gene comprising the mutation through the germline of a non-human animal. For example, the above-mentioned studies required working with chimeric mice that possess in some cells the indicated mutation but that are unable to transmit the mutation in the germline; thus, a stable and useful mouse line has not been established that comprises the R206H mutation in the germline. There remains a need for non-human animals that can transmit an ACRV1 mutation that is perinatal or embryonic lethal in the germline to produce progeny that are useful, e.g., to produce a non-human animal that exhibits a phenotype associated with the ACRV1 mutation, e.g. FOP, an FOP feature, or a feature of a related disorder, or a related disorder. SUMMARY [0006] Genetically modified non-human animals are provided that comprise in their germline a nucleic acid sequence that comprises a modification of an Acvr1 gene. [0007] Genetically modified non-human animals are provided that comprise in their germline a nucleic acid sequence that comprises a conditional genetic modification of an Acvr1 gene, wherein the genetic modification renders the non-human animal susceptible to ectopic bone formation. [0008] Genetically modified non-human animals are provided that comprise in their germline a nucleic acid sequence that comprises a conditional genetic modification comprising a conditional mutant Acvr1 exon, wherein induction of expression of the conditional mutant Acvr1 exon confers upon the non-human animal a susceptibility to ectopic bone formation. In one embodiment, the mutant Acvr1 exon is exon 5. In a specific embodiment, the mutation expresses an Amid-encoded protein having an exon 5 with a R2026H mutation. [0009] Non-human animals are provided that conditionally express a mutant Amid allele. In various aspects, the mutant Amid allele is an allele that confers a pathological phenotype on the non-human animal expressing the allele. In various aspects, the non-human animals comprise a mutant exon of an Amid allele flanked upstream and downstream with site-specific recombinase recognition sites (SRRS's), and the non-human animal comprises a recombinase that recognizes the SRRS's, wherein the recombinase is inducible. [0010] Non-human animals are provided that comprise a modification of an Amid allele that causes (in one embodiment, in a heterozyogte; in one embodiment, in a homozygote), promotes, or makes the non-human animal susceptible to ectopic ossification. [0011] Non-human animals are provided that comprise a conditional mutation of an Amid allele, wherein the mutant Amid allele is not expressed in utero, and is not expressed perinatally, and wherein the non-human animals express the mutant Amid allele in a conditional manner, wherein the conditional expression is induced by administration of a compound of interest to the non-human animal. [0012] Acvr1 loci are provided that comprise a modification that comprises a conditional mutant exon, wherein the conditional mutant exon is expressed upon an experimentally-induced induction. [0013] In one aspect, a genetically modified Acvr1 locus is provided, comprising a mutant exon in antisense orientation, flanked upstream and downstream by SRRS's. In one embodiment, the locus is present in a non-human animal that further comprises an inducible recombinase gene that recognizes the SRRS's that flank the mutant exon. [0014] In one aspect, a non-human animal is provided that comprises a modified Acvr1 locus comprising a mutant exon in antisense orientation, wherein the mutant exon is flanked upstream and downstream by RSSR's that are oriented to direct an inversion when acted upon by a recombinase that recognizes the RSSR's. In one embodiment, the mutant exon upon inversion replaces the corresponding wild-type exon of the Acvr1 locus. In one embodiment, the non-human animal further comprises an inducible recombinase gene, wherein the recombinase of the inducible recombinase gene recognizes the RSSR's. In a specific embodiment, the RSSR's are lox sites or variants thereof, the recombinase is Cre, and the recombinase is inducible by tamoxifen. In a specific embodiment, the recombinase is a Cre-ER T2 . In one embodiment, the non-human animal is a rodent, e.g., a mouse or rat. In a specific embodiment, the rodent is a rat, and the mutant Acvr1 exon is exon 5. [0015] In one aspect, a genetically modified mouse is provided that comprises a nucleic acid construct comprising a mutant exon 5 (e5) encoding an R206H mutation, wherein the mutant e5 is present in antisense orientation and is flanked upstream and downstream by RSSRs oriented to direct an inversion of the mutant e5; and the mouse comprises an inducible recombinase gene encoding a recombinase that is capable of inverting the antisense mutant e5 exon to sense orientation. [0016] In one aspect, a genetically modified mouse is provided that comprises a nucleic acid construct at an Acvr1 locus in the germline of the mouse, wherein the nucleic acid construct comprises, with respect to the direction of transcription of the Acvr1 gene, a construct comprising a wild-type e5 gene in sense orientation and a mutant e5 allele in antisense orientation, wherein upstream of the wild-type e5 allele is a first RSSR (RSSR1) that is compatible with a second RSSR (RSSR2) located just downstream (with respect to transcriptional direction of the Acvri gene) of the antisense mutant e5, wherein RSSR1 and RSSR2 are oriented to direct an inversion. The construct further comprises a third RSSR (RSSR3) disposed between the wild-type e5 and the mutant antisense e5, and the construct further comprises a fourth RSSR (RSSR4) that is compatible with RSSR3, and which is located downstream (with respect to the direction of orientation of the Acvr1 gene) of RSSR2, wherein RSSR3 and RSSR4 are oriented to direct an inversion. Each RSSR (1-4) is recognized by the same inducible recombinase. [0017] In one embodiment, the inducible recombinase is in the germline of the mouse. [0018] In one embodiment, the RSSR sites are recognizable by a Ore recombinase. [0019] In one embodiment, RSSR1 and RSSR2 are 1ox2372 sites; RSSR3 and RSSR4 are loxP sites, and the inducible recombinase is a CreER T2 (see, e.g., FIG. 1 ). [0020] In one embodiment, RSSR1 and RSSR2 are loxP sites; RSSR3 and RSSR4 are 1ox2372 sites, and the inducible recombinase is a CreER T2 (see, e.g., FIG. 1 ). [0021] In one embodiment, the CreER T2 is present at the ROSA26 locus (e.g., Gt(ROSA26)Sor CreERT 2/+. [0022] In one aspect, a genetically modified mouse is provided comprising the genotype Acvr1 [R206H]COIN/+ ; Gt(ROSA26)Sor CreERt2/+ . [0023] In one aspect, a genetically modified rodent is provided that expresses a normal Acvr1 exon 5 in utero and perinatally, wherein upon treatment of the genetically modified rodent with a recombinase, the mouse expresses an Acvr1-encoded protein that comprises a mutation encoded by exon 5. In one embodiment, the mutation is an exon 5 mutation that encodes a R206H mutation. [0024] In one aspect, an adult rodent is provided that expresses a mutant Acvr1 gene product characterized by a R206H modification, wherein at least 99% of the cells of the mouse comprise a mutant Acvr1 gene encoding the R206H modification. [0025] In one aspect, a genetically modified rodent is provided that comprises a mutant Acvr1 gene product characterized by a R206H modification, wherein the mutant Acvr1 gene is present in at least 90%, 95%, 96%, 97%, 98%, or 99% or more of the cells of the genetically modified rodent. [0026] In one aspect, a genetically modified rodent is provided, wherein the rodent comprises an Acvr1 locus in its germline that, upon exposure to a recombinase, expresses a protein encoded by the Acvr1 locus that comprises a R206H modification. [0027] In one aspect, a rodent is provided that expresses a mutant protein comprising a R206H mutation, wherein the mouse is non-chimeric. In one embodiment, the extent of chimerism of the rodent is no more than 1%. [0028] In one aspect, a mouse is provided that expresses a mutant protein from a modified Acvr1 locus in the germline of the mouse, wherein all Acvr1-expressing cells of the mouse comprise a modified Acvr1 gene that encodes an Acvr1 protein that comprises an R206H modification. In one embodiment, all germ cells of the mouse comprise a modified Acrv1 locus comprising a conditional genetic modification that encodes an Acvr1 protein with an R206H modification. [0029] In one aspect, a genetically modified mouse comprising an engineered Acvr1 [R206H]COIN allele is provided, wherein the first codon of human ACVR1 exan 5 (isoform 003) is modified encode an E, wherein at the protein level the humanized exon is identical to the wild type mouse Acvr1 exon 5 (isoform 001). [0030] In one aspect, a mouse is provided that comprises a conditional genetic modification of an Acvr1 gene, wherein the modification changes an amino acid in an ACVR1 α-helix comprising ACVR1 amino acids 198-206 and results in a constitutive activation of the protein encoded by the Acvr1 locus. [0031] In one embodiment, the conditional genetic modification is in an amino acid selected from amino acid 198, 199, 200, 201, 202, 203, 204, 205, 206, and a combination thereof. In a specific embodiment, the amino acid is 206, and the modification is a nucleotide change that forms a codon for histidine. [0032] In one embodiment, the mouse is heterozygous for the conditional genetic modification. In one embodiment, the mouse is homozygous for the conditional genetic modification. [0033] In various aspects, the non-human animal is a mammal. In one embodiment, the mammal is a rodent. In one embodiment, the rodent is selected from the group consisting of a mouse, a rat, and a hamster. In a specific embodiment, the rodent is a mouse. [0034] In various aspects, the genetically modified non-human animal comprises an array of RSSR's that are arranged to direct a deletion of a wild-type Acvr1 exon 5 and place a mutant exon 5 from an antisense orientation to a sense orientation. [0035] In various aspects, the genetically modified non-human animal further comprises an inducible recombinase that acts upon a nucleic acid construct in the Acvr1 locus to remove the wild-type exon and replace it with the mutant exon. In one embodiment, the inducible recombinase is CreER T2 . [0036] In various aspects, the genetically modified non-human animals, upon expression of the mutant Acvr1 allele, are capable of expressing the alternate (wild-type) allele. [0037] In various aspects, the genetically modified non-human animal that expresses the mutant Acvr1 allele is a model for an ectopic ossification disorder. In one embodiment, the ectopic ossification disorder is fibrodysplasia ossificans progressiva (FOP). [0038] In various aspects, genetically modified non-human animals are provided that conditionally express a mutant Acvr1 allele comprising a mutant exon 5 (e.g., expressing a protein comprising an R206H mutation) upon exposure to tamoxifen, wherein the non-human animals comprise a tamoxifen-inducible recombinase that converts a wild-type exon 5 to a mutant exon 5 within the Acvr1 gene. BRIEF DESCRIPTION OF THE DRAWINGS [0039] FIG. 1 illustrates design of a conditional allele at an Acvr1 locus that converts, e.g., a mouse Acvr1 exon 5 to a human R206H exon using loxp and 1ox2372 sites. [0040] FIG. 2 illustrates design of a conditional allele of Acvr1 R206H classic FOP mutant receptor gene. Mouse Exon 5 (e5 in isoform 001) is replaced with human exon 5 (in human ACVR1 isoform 003); a mouse mutant exon is simultaneously introduced in the antisense strand, together with a FRT'ed selection cassette (hUB-Neo); human e5 is flanked with loxP and lox2372 pointing East, and another loxP and Lox2372 sites are placed downstream of mouse e5(R206H) and deletion of the human e5, upon exposure to Cre, as detailed schematically in FIG. 1 [0041] FIG. 3 illustrates activation of the Acvr1 [R206H]COIN allele results in an FOP-like phenotype in mice genetically modified with the conditional allele. [0042] FIG. 4 illustrates ectopic bone formation in genetically modified mice comprising the conditional allele induced in mice administered tamoxifen; an example of ectopic bone formation at the sternum is indicated in the right panel with white arrows. In the absence of tamoxifen (left panel), no ectopic bone formation is detected. [0043] FIG. 5 provides another illustration of ectopic bone formation in genetically modified mice comprising the conditional allele induced in mice administered tamoxifen; an example of ectopic bone formation at the sternum is indicated in the right panel with white arrows. In the absence of tamoxifen (left panel), no ectopic bone formation is detected. [0044] FIG. 6 provides yet another illustration of ectopic bone formation in genetically modified mice comprising the conditional allele induced in mice administered tamoxifen; an example of ectopic bone formation at the sternum is indicated in the right panel with white arrows. In the absence of tamoxifen (left panel), no ectopic bone formation is detected. [0045] FIG. 7 illustrates control mice (left panels, ID 840095); and ectopic bone formation in genetically modified mice comprising the conditional allele induced in mice administered tamoxifen (Tamoxifen #2, ID:845202); top right panel shows ectopic bone formatoin at the sternebra; bottom right panel shows ectopic bone formation at the hip joint and the caudal vertebrae. [0046] FIG. 8 illustrates ectopic bone formation at the sternebra (left panel) and the caudal vertebrae (right panel) for genetically modified mice comprising the conditional allele induced in mice administered tamoxifen (Tamoxifen #3, ID:915546). [0047] FIG. 9 illustrates the absence of ectopic bone formation in genetically modified mouse comprising the conditional allele, induced with tamoxifen (Tamoxifen #4, ID:904067). [0048] FIG. 10 illustrates ectopic bone formation at the sternebra (left panel) in genetically modified mice comprising the conditional allele induced by administration of tamoxifen (Tamoxifen #5, ID:840098). [0049] FIG. 11 illustrates ectopic bone formation at the sternebra (left panel) and knee joint (right panel) in genetically modified mice comprising the conditional allele induced by administration of tamoxifen (Tamoxifen #6, ID:863713). [0050] FIG. 12 illustrates primers and probes used in a loss of allele assay to genotype genetically modified mice comprising the conditional mutation in the Acvr1 gene; SEQ ID NOs are, from top to bottom: for the forward primer from top to bottom SEQ ID NO:1, SEQ ID NO:2; for the reverse primer from top to bottom SEQ ID NO:3, SEQ ID NO:4; for the probe SEQ ID NO:5, SEQ ID NO:6. DETAILED DESCRIPTION [0051] Fibrodysplasia ossificans progressiva (FOP) is an autosomal dominant disorder of ectopic bone formation. Linkage studies in affected families reveal that the FOP gene maps to chromosome 2q23-24 where a 617G-to-A mutation (R206-to-H) in the activation domain of activin A type I receptor gene (Acvr1) was found on all affected individuals examined in the studies (Shore et al., (2006) A recurrent mutation in the BMP type I receptor Acvr1 causes inherited and sporadic fibrodysplasia ossificans progressiva, Nat. Genet. 38:525-527), consistent with FOP being caused by constitutive activation of Acvr1 (Id.). [0052] Genetically modified mice are provided that express an Acvr1 protein comprising a modification that results in a disorder characterized by ectopic bone formation, e.g., FOP. Mice expressing the modified Acvr1 protein include mice that are not chimeric, e.g., mice whose genomes carry a (conditional) modification of the Acvr1 protein that results in ectopic bone formation in a mouse that expresses the modified Acvr1 protein. [0053] Certain mutations in the Acvr1 protein, e.g., the FOP-associated R206H mutation, are difficult if not impossible to create in the germline of mice due to embryonic or perinatal fatality associated with the mutation. Genetically modified mice are provided that comprise an COnditional-by-INversion (COIN) design that provides for a conditional inversion and removal of a wild-type exon and replacement of the wild-type exon with a mutant exon. This COIN design allows for forming a conditional allele by placement of a nucleic acid sequence encoding an inverted mutant exon to be placed next to a wild-type exon to be deleted. Through selection of recombinase recognition sites (RRS's), the inverted mutant exon is reversed to place it in reading frame whereas the wild-type exon is deleted. This COIN approach relies on the placement of incompatible RSS's (e.g., 1ox2372 and loxp) surrounding the wild-type and mutant exons. This COIN approach thus does not allow for expression of the (perinatal/embryonic) lethal mutation unless the COIN allele is acted upon by the selected recombinase(s). Another advantage of this COIN approach is permanent removal of the wild-type exon upon exposure to the selected recombinase, and thus no inverted repeat remains in the genome post-inversion. This is advantageous because it eliminates the possibility of re-inversion, because the remaining recombinase sites are incompatible (e.g., 1ox2372 and loxP). In this instance, humanization of the wild-type mouse exon also minimizes inverted repeat sequence, thus facilitating cloning steps and alleviating concerns of rearrangements during and after targeting. [0054] If a mouse bearing the COIN allele is bred to a recombinase-containing mouse, the (perinatal/embryonic) lethal mutation will express in the progeny in utero, thus confounding the goal of making an animal that can be studied which expresses the allele. Therefore, the mouse bearing the COIN allele is not bred with an unregulated recombinase-containing mouse. Instead, the mouse is bred with a mouse that contains a Cre-ER protein that this modified with T2 mutations (a Cre-ER T2 mouse), or modified to contain a Cre-ER T2 allele. The Cre-ER T2 protein is a Cre protein modified with an estrogen receptor sequence that comprises T2 mutations that render the Cre protein inactive (see, Indra, A. et al. (1999) Temporally-controlled site-specific mutagenesis in the basal layer of the epidermis: comparison of the recombinase activity of the tamoxifen-inducible Cre-ER T and Cre-ER T2 recombinases, Nucleic Acids Res. 27(22):4324-4327; Feil, R. et al. (1997) Regulation of Cre Recombinase Activity by Mutated Estrogen Receptor Ligand-Binding Domains, Biochem. Biophys. Res. Commun. 237:752-757; U.S. Pat. No. 7,112,715). A mouse comprising a conditional allele constructed with Cre-responsive RSS's as described herein, and containing a Cre-ER T2 allele, would therefore express the wild-type allele unless and until the mouse was exposed to tamoxifen to induce Cre activity. In this way, mice are made that contain a mutant Acvr1 allele in their germline but that do not express a mutant Acvr1 protein unless and until the mice are exposed to tamoxifen. Following exposure to tamoxifen, the Cre-ER T2 fusion protein is activated and the conditional allele converts to a mutant allele and, in various embodiments, the conversion to the mutant allele is irreversible, with deletion of the wild-type allele. In this manner, a mouse line containing an otherwise lethal Acvr1 mutation can be maintained essentially indefinitely, producing the desired genetic lesion and accompanying phenotype whenever desired. In various embodiments, a genetically modified mouse comprising the Acvr1 COIN allele is made by modifying a mouse ES cell to contain the COIN allele, and modifying the same ES cell to contain a gene encoding the tamoxifen-inducible Cre-ER T or Cre-ER T2 , and using the ES cell as a donor cell to make a mouse that contains the COIN allele and the modified Cre gene. All of the references cited herein are hereby incorporated by reference. [0000] Engineering a Conditional ACVR1 Allele that is Germline Transmissible [0055] In order to engineer a mouse model of Fibrodysplasia Ossificans Progressiva (FOP), the R206H “classic FOP” mutation of human Acvr1 (Shore et al. (2006)) was engineered into the corresponding mouse gene, Acvr1. This mutation has already been modeled non-conditionally in the mouse, but the resulting chimeric mice (arising from blastocyst microinjection of the targeted ES cells) were unable to transmit the mutation through the germline, presumably due to embryonic or perinatal lethality (Chakkalakal, S. A. et al. (2012) An Acvr1 R206H knock-in mouse had fibrodysplasia ossificans progressiva, J. Bone and Mineral Res. 27:1746-1756). Prior to knowledge of this phenotype, and based on the phenotype of Acvr1 homozygous-null mice, which reveals a profound role of Amid during development (Mishina et al. (1999) Multiple roles for activin-like kinase-2 signaling during mouse embryogenesis, Dev. Biol. 212:314-326), it was decided to engineer the Acvr1 [R206H] mutation in a conditional manner in the mouse, utilizing a variation on FIEx (Schnutgen, F. et al. (2003) A directional strategy for monitoring Cre-mediated recombination at the cellular level in the mouse, Nat. Biotech. 21:562-565) and COIN (U.S. Pat. No. 7,205,148) methodologies. [0056] FIEx employs a pair of mutant Lox sites—referred to as a FIEx array—that are recognized by the same recombinase—Cre—but which to do not react with one another, and laid out in an A-B/[A-B] configuration, where the “[A-B]” is in the opposite strand with respect to “A-B”, to enable inversion of the DNA sequence flanked by the arrays. In its published embodiment, FIEx utilized sites LoxP and Lox511. Less known, however, is that in the presence of Cre a low level of recombination takes place between LoxP and Lox511. Therefore, different combinations of Lox site variants were tested, and the LoxP-Lox2372 combination were selected for the conditional allele described herein, because these two sites did not exhibit any cross-reactivity. An additional feature of FIEx is that the sequence that is contained within each array—i.e., between the LoxP and Lox2372 sites of each array—will be deleted upon action by Cre. The engineering of the allele of the invention (Acvr1 [R206H]COIN allele) takes into account these two properties of FIEx. One embodiment of an conditional allele is illustrated in FIG. 2 . [0057] Mouse Acvr1 displays a variety of splice variants (e.g., 201, 202, 001, 003, 004). exon 5, which is mutated in FOP, is shared by all protein-coding splice variants of Acvr1. In one embodiment, the genetically modified mouse comprises a modification of exon 5 of an isoform selected from the group consisting of 201, 202, 001, 003, and 004. [0058] The Acvr1 [R206H]COIN allele was engineered by placing the mutant version of the R206-encoding exon of mouse Acvr1 (ENSMUSE00001021301) in the antisense strand, so that it is not incorporated into Acvr1's transcript. As the sequence encoded by exon 5 is required for Acvr1 function, this necessitated that an exon encoding for the wild type exon 5's sequence is also incorporated into the design (exon 5 is shared by all protein-coding splice variants of Acvr1). Furthermore, since exons are not recognized as such without accessory intronic sequences, both upstream and downstream of the exon had to be incorporated into both mutant and wild type R206-encoding exon. However, doing so would generate a large inverted repeat, and such DNA structures are inherently prone to recombination both during the genetic engineering steps required to build the targeting vector as well as post-targeting, in vivo (Holkers, M. et al. (2012) Nonspaced inverted DNA repeats are potential targets for homology-directed gene repair in mammalian cells, Nucleic Acids Res. 40:1984-1999). Furthermore, if the wild type mouse sequence of the R206-encoding exon and the upstream and downstream intronic sequence associated with it were retained intact, and precede the mutant exon, then this wild type region could act as a homology arm and be utilized during targeting in the mouse ES cells, thereby resulting in exclusion of the mutated exon from the targeted allele. Therefore, in order to address all these concerns the Acvr1 [R206H]COIN allele was designed in a manner such that: (a) A large inverted repeat is avoided. To accomplish this, the R206-encoding exon (ENSMUSE00001021301) as well associated upstream and downstream intronic sequences were replaced with the corresponding region from human ACVR1. (b) The wild type mouse sequence of the R206-encoding exon (ENSMUSE00001021301) is preserved at the protein level. Given that the mouse and human protein sequence respectively encoded by exons ENSMUSE00001021301 and ENSE00001009618 differ by one amino acid, the human ENSE00001009618 exon sequence was altered so as to match the mouse protein sequence of exon ENSMUSE00001021301. [0061] (c) The introduced human sequence is removed in its entirety upon action with Cre. Therefore, in the “conditional-on” state—where the Acvr1 [R206H] mutant gene is transcribed—no human sequences remain and hence any resulting phenotype cannot be attributed to the presence of extraneous sequence. [0062] More specifically, the region bounded by nucleotides 58474046 to 58474368 in mmuAcvr1 (i.e., nucleotides 58474046 to 58474368 of mouse Chromosome 2) where replaced with nucleotides 15863048 to 158630803 of hsaACVR1 (i.e., nucleotides 15863048 to 158630803 of human Chromosome 2), in a manner such that the introduced sequence, which includes hsaACVR1 exon ENSE00001009618 is transcribed as part of the resulting modified Acvr1 [R206H]COIN locus. In addition, the coding sequence of the first amino acid of human exon [0063] ENSE00001009618 was replaced from aspartic acid (D) to glutamic acid (E) to correspond at the protein level to the exactly the same protein sequence as that encoded by mouse exon ENSMUSE00001021301. (This introduced human sequence is referred to hereafter as hsa_e5+.) Therefore, prior to inversion of the COIN element (mutated exon ENSMUSE00001021301 and associated upstream and downstream intronic sequences—see below), the resulting locus, Acvr1 [R206H]COIN , should function as wild type. [0064] The R206H mutation was modeled by mutating exon ENSMUSE00001021301 in the corresponding position, by altering the codon defined by nucleotides 5847419 to 58474200 from CGC (coding for arginine) to CAC (coding for histidine). The resulting mutant exon, along with flanking intronic sequences upstream and downstream were placed 3′ to hsa_e5+ and in the antisense strand of mmuAcvr1, replacing nucleotides 58473775 to 58473879 of mmuAcvr1 in order to also create a small deletion and accommodate LOA probes (Gomez-Rodriguez, J. et al. (2008) Advantages of q-PCR as a method of screening for gene targeting in mammalian cells using conventional and whole BAC-based constructs, Nucleic Acids Res. 36:e117; Valenzuela, D. et al. (2003) High-throughput engineering of the mouse genome coupled with high-resolution expression analysis, Nat. Biotech. 21:652-659). (This introduced mutated mouse sequence is hereafter referred to as mmu_e5R206H+.) [0065] In order to enable Cre-dependent inversion of the mmu_e5R206H+ and simultaneous deletion of hsa_e5+, a combination of FIEx like Lox arrays where used such that: (a) hsa_e5+is preceded by a LoxP site, and followed by a Lox2372 site. In this respect, hsa_e5+is contained with the 5′ LoxP-Lox2372 FIEx-like array. (b) mmu_e5R206H+is followed by the 3′ LoxP-Lox2372 FIEx-like array, but this array is engineered such that it is in a mirror image configuration to 5′ LoxP-Lox2372 FIEx-like array. This enables permanent inversion of mmu_e5R206H+into the sense strand by Cre. [0068] When the resulting allele, Acvr1 [R206H]COIN is exposed to Cre, the hsa_e5+ will be deleted and the mmu e5R206H+will be inverted into the sense strand. As a result, Acvr1 [R206H] will be expressed in place of Acvr1. [0069] Genetically modified mice were genotypes employing a loss of allele assay (see, e.g., Valenzuela et al., (2003), supra). Primers and probes were as shown in FIG. 12 (Table 5). [0000] Phenotype of Acvr1 R206HCOIN/+ mice [0070] Acvr1 R206HCOIN/+ mice are phenotypically normal but develop FOP after activation of the R206H conditional mutation. [0071] Based on published results with a non-conditional, simple knock-in Acvr1 R206H chimeric mouse (Chakkalakal et al., 2012) as well as the fact that FOP is an autosomal-dominant disorder (for a review see (Pignolo et al., 2011)), it was hypothesized that: (a) Unlike the non-conditional Acvr1 R206H allele (Chakkalakal et al., 2012), targeted ES cells for Acvr1 [R206H]COIN will produce VELOCIMICE®, i.e., FO mice that are entirely derived from the targeted ES cells (Poueymirou et al. (2007) FO generation mice fully derived from gene-targeted embryonic stem cells allowing immediate phenotypic analyses, Nat. Biotech. 25:91-99). (b) Unlike the non-conditional Acvr1 R206H/+ chimeric mice (Chakkalakal et al., 2012), F0 Acvr 1 [R206H]COIN/+ mice will be phenotypically normal, and will transmit the Acvr1 [R206H]COIN allele to the next generation. (c) Upon inversion of mutant exon bearing the R206H mutation into the sense strand—an action mediated by Cre recombinase—cells that have been converted to the Acvr1 [R206H]INV/+ genotype will express the mutant Acvr1 [R206H] allele as well as the wild-type allele, mirroring the situation in FOP patients. Along the same lines, the resulting Acvr1 [R206H]INV/+ mice should overtime develop FOP-like symptoms. [0075] All of these hypotheses were born out. For example, ES cell clone 1649C-A2 gave rise to 16 VELOCIMICE® out of 19 mice generated using that clone (Table 1). [0000] TABLE 1 Acvr1 [R206H]COIN/+ ES Cells Give Rise Mainly to Male F0 Mice Wholly Derived from Donor ES Cells Mouse ID Chimerism (%) 1649C-A2/758470 100 1649C-A2/758471 100 1649C-A2/758472 100 1649C-A2/758473 100 1649C-A2/758474 100 1649C-A2/758475 100 1649C-A2/758476 100 1649C-A2/758477 100 1649C-A2/758478 100 1649C-A2/758479 100 1649C-A2/758480 100 1649C-A2/758481 100 1649C-A2/758482 100 1649C-A2/758483 100 1649C-A2/758484 100 1649C-A2/758485 100 1649C-A2/758486 80 1649C-A2/758487 70 1649C-A2/758488 30 [0076] Furthermore, these mice had no discernible phenotype and were able to reproduce and father Acvr1 [R206H]COIN/+ F1 generation mice (Table 2). [0000] TABLE 2 F1 Mice Born to Acvr1 [R206H]COIN/+ F0 Fathers Clone Name/ID Genotype Gender 1649C-A2/2251A-C6/840095 1649 Het 2251 Het M 1649C-A2/2251A-C6/840098 1649 Het 2251 Het M 1649C-A2/2251A-C6/845202 1649 Het 2251 Het M 1649C-A2/2251A-C6/845203 1649 Het 2251 Het F 1649C-A2/2251A-C6/845204 1649 Het 2251 Het F 1649C-A2/2251A-C6/845205 1649 Het 2251 WT F 1649C-A2/2251A-C6/845809 1649 Het 2251 WT F 1649C-A2/2251A-C6/863706 1649 Het 2251 WT F 1649C-A2/2251A-C6/863707 1649 Het 2251 WT F 1649C-A2/2251A-C6/863713 1649 Het 2251 Het M 1649C-A2/2251A-C6/863714 1649 Het 2251 WT M 1649C-A2/2251A-C6/897113 1649 Het 2251 WT F 1649C-A2/2251A-C6/897115 1649 Het 2251 WT F 1649C-A2/2251A-C6/897117 1649 Het 2251 Het F 1649C-A2/2251A-C6/904065 1649 Het 2251 WT M 1649C-A2/2251A-C6/904067 1649 Het 2251 Het M 1649C-A2/2251A-C6/904069 1649 Het 2251 WT F 1649C-A2/2251A-C6/904783 1649 Het 2251 WT M 1649C-A2/2251A-C6/904785 1649 Het 2251 WT F 1649C-A2/2251A-C6/907167 1649 Het 2251 WT F 1649C-A2/2251A-C6/915545 1649 Het 2251 WT M 1649C-A2/2251A-C6/915546 1649 Het 2251 Het M 1649C-A2/2251A-C6/964988 1649 Het 2251 Het F 1649C-A2/2251A-C6/964989 1649 Het 2251 Het F F1 generation Acvr1 [R206H]COIN/+ ; Gt(ROSA26)Sor CreERt2/+ mice born to Acv1 [R206H]COIN/+ F0 [0077] From a phenotypic standpoint, Acvr1 [R206H]COIN/+ mice appear normal, and display no discernible phenotypes. The same applies to Acvr1 [R206H]COIN/+ ; Gt(ROSA26)Sor CreERt2/+ mice, which in addition to the Acvr1 [R206H]COIN/+ allele also carry a CreER T2 transgene knocked into the Gt(ROSA26)Sor locus. This allows ubiquitous expression of an inactive version of Cre, one that is dependent upon tamoxifen for activation (Feil et al. (1997) Regulation of Cre recombinase activity by mutated estrogen receptor ligand-binding domains, Biochem. Biophys. Res. Commun. 237:752-757). This enables the activation of Cre at a specific point in time, and hence not only allows bypassing the embryonic lethality experienced with the conventional Acvr1 [R206H] knock-in of but also empowers the investigator to choose the time of activation of the Acvr1 ]R206H] expression in the corresponding mice. [0078] In order to investigate whether Acvr1 [R206H]COIN/+ ; Gt(ROSA26)Sor CreERt2/+ mice develop FOP after exposure to tamoxifen, we generated a small cohort and treated it with tamoxifen starting at approximately one year of age (Table 3); it is notable that by this age mice have completed their development, and therefore no modeling or development-related mechanisms are at play and therefore cannot contribute to the pathological process. Delivery of tamoxifen was by injection into the peritoneum using a 10 mg/mL solution in corn oil. Injections were performed daily for 8 days. In three mice (Mice 1, 2, and 3 of Table 3), a small piece of muscle was resected to induce injury. [0000] TABLE 3 Protocol for Cre-Mediated Tamoxifen-Dependent Activation of Acvr1 [R206H]COIN Allele in Acvr1 [R206H]COIN/+ ; Gt(ROSA26 )CreERt2/+ Mice Age at Sacrifice Mouse Daily Start Start End Sacrifice Age Mouse ID Injection Day (yrs) Day Day (yrs) 1 840095 corn oil 1 0.9  8 143 1.3 2 845202 TAM* 1 0.9  8 143 1.3 3 915546 TAM  1 0.56 8 143 1.0 4 904067 TAM  1 0.61 8 143 1.0 5 840098 TAM  1 0.90 8 143 1.3 6 863713 TAM  1 0.80 8 143 1.2 TAM: tamoxifen [0079] All but one of the tamoxifen-treated mice developed ectopic ossification, mirroring what has been observed in FOP (Table 4). Although the specific cell type(s) that might be contributing to the disease process were not determined in this experiment due to the fact that the expression of CreER t2 is ubiquitous (a property imparted by the fact that it is expressed from the Gt(ROSA26)Sor locus), one of the important aspects of this work is that it removes the developmental aspects of FOP (which are not those most important to FOP's pathology, as they do not contribute to the devastating loss in quality of life the FOP patients experience), and shows that the ectopic bone formation that is the major post-natal hallmark of FOP pathology is independent of developmental processes. [0000] TABLE 4 Four Acvr1 [R206H]COIN/+ ; Gt(ROSA26) CreERt2/+ Mice Exposed to Tamoxifen Develop FOP-Like Skeletal Pathology Mouse Mouse ID Ectopic Bone Formation 1 840095 None* 2 845202 sternebra, hip joint, caudal vertebrae 3 915546 sternebra, hip joint, caudal vertebrae 4 904067 none 5 840098 sternebra 6 863713 sternebra, knee joint *Treated with corn oil (vehicle) only, not tamoxifen [0080] Ectopic ossification is shown in images of genetically modified mice as described herein exposed to tamoxifen (which display ectopic ossification). Mice that are genetically modified as described herein but not exposed to tamoxifen do not display ectopic ossification See, e.g., FIG. 3 , FIG. 4 , FIG. 5 , FIG. 6 , FIG. 7 , FIG. 8 , FIG. 10 , and FIG. 11 . Ectopic ossification is demonstrated in a variety of body areas. As shown in FIG. 9 , one mouse showed no apparent ectopic bone formation.
A genetically modified mouse is provided that comprises a conditional Acvr 1 allele that comprises a mutated exon that, upon induction, converts to a mutant exon phenotype, wherein the mutant exon phenotype includes ectopic bone formation. Mice comprising a mutant Acvr1 exon 5 in antisense orientation, flanked by site-specific recombinase recognition sites, are provided, wherein the mice further comprise a site-specific recombinase that recognizes the site-specific recombinase recognitions sites, wherein the recombinase is induced upon exposure of the mouse to tamoxifen. Upon exposure to tamoxifen, the recombinase is expressed and acts on the RRS-flanked mutant exon 5 and places the mutant exon 5 in sense orientation and deletes the wild-type exon.
2
CROSS-REFERENCE TO RELATED APPLICATION(S) The present application claims the benefit of priority of Japanese Patent Application No. 2012-092855, filed on Apr. 16, 2012. The disclosures of the application are incorporated herein by reference. BACKGROUND 1. Technical Field The present disclosure relates to a wireless network system, more particularly, to a wireless network system to which a plurality of devices operating on the basis of incompatible and different standards are connected and the plurality of devices operating on the basis of the respective standards can operate stably while being mixed. 2. Related Art Process control systems in recent industrial automation are frequently configured using wireless field devices serving as a kind of wireless communication apparatus. As these wireless field devices, devices designed on the basis of the industrial automation wireless communication standard ISA100.11a drawn up by the ISA100 Committee of the International Society of Automation (ISA) and issued on September, 2009 are used, for example. As a result that a related-art process control system is configured using wired field devices connected via cables, the process control system is affected by, for example: 1) Restriction on communication distance 2) Restriction on cable routing Hence, sensors for measuring predetermined physical quantities serving as targets to be measured, such as temperature and flow rate, cannot be installed at optimal positions inside a plant, thereby causing a problem that the control accuracy of the process control system is degraded. The above-mentioned approach is taken to solve this problem. FIG. 4 is a configuration explanatory view showing an example of a wireless network system having been used in the related art. In FIG. 4 , a wireless network 1 is configured as a star-mesh topology composed of a plurality of I/O devices 2 to 6 , routing devices 7 and 8 , and a gateway 9 . The I/O devices 2 to 6 have the wireless communication functions specified in the ISA100.11a and include various sensors, such as differential pressure/pressure transmitters and temperature transmitters, and various final control elements, such as valves and positioners. The routing devices 7 and 8 , serving as advertisement routers, have functions for periodically issuing advertisement to neighboring devices, thereby transmitting route information and messages. These routing functions may be provided for sensors, such as differential pressure/pressure transmitters and temperature transmitters, and final control elements, such as valves and positioners, in some cases. The gateway 9 has a function for connecting the wireless network 1 to a plant network 10 and also has a function for connecting the plurality of I/O devices 2 to 6 to a host application 11 provided for the plant network 10 . Furthermore, the gateway 9 can be equipped with a system manager function and a security manager function for the wireless network topology as necessary, thereby being capable of managing the system and security of the wireless network topology. Moreover, the gateway 9 can be equipped with a backbone router function for performing connection to wireless connection devices. The host application 11 performs the setting of the routing devices 7 and 8 and the I/O devices 2 to 6 , the diagnosis of devices, and the upgrade of firmware. When attention is paid to wireless communication inside the wireless network 1 configured as shown in FIG. 4 , the I/O devices 2 and 3 perform communication with the gateway 9 via the routing device 8 , and the I/O devices 4 to 6 perform communication with the gateway 9 via the routing device 7 . When the above-mentioned wireless communication is performed, in order that the presence or absence of transmission errors is identified accurately, the calculation result of an MIC (Message Integrity Code: manipulation detection code) based on a cipher set beforehand on the transmitting side is added and transmitted. Also on the receiving side, an MIC is calculated on the basis of a cipher key common to the transmitting side, and the result of the calculation is compared and checked with the received MIC. The presence or absence of transmission errors is then judged depending on whether the two MICs are coincident with each other. FIG. 5 is a block diagram showing an example of a processor 20 on the receiving side, and FIG. 6 is a flowchart illustrating an example of the flow of MIC processing at the time when data is received in the processor 20 on the receiving side shown in FIG. 5 . Referring to FIGS. 5 and 6 , when a data receiver 21 receives data transmitted from the transmitting side (at step S 1 ), an MIC detector 22 detects the MIC that was calculated and added to the data on the transmitting side (at step S 2 ), and an MIC calculator 23 calculates an MIC on the basis of the cipher key common to the transmitting side (at step S 3 ). An MIC comparator 24 compares and checks the MIC detected by the MIC detector 22 with the MIC calculated by the MIC calculator 23 , thereby judging whether the two are coincident with each other (at step S 4 ). In the case that the two are coincident with each other, the MIC calculated by the MIC calculator 23 is added to an acknowledge signal ACK generated by an ACK generator 25 and then transmitted to the transmitting side via a data transmitter 26 (at step S 5 ). On the other hand, in the case that the two are not coincident with each other, the MIC calculated by the MIC calculator 23 is added to a non-acknowledge signal NACK generated by an NACK generator 27 and then transmitted to the transmitting side via the data transmitter 26 (at step S 6 ). Non-patent Document 1 discloses a concept of a field wireless solution conforming to ISA100.11a and a concept of a field wireless system in which a central focus is placed on DCS. Non-patent Document 2 discloses a technology relating to wireless field devices and a field wireless system conforming to ISA100.11a. Patent Document 1 discloses a technology for preventing terminals from malfunctioning even in the case that a communication network is structured so that old terminals operating according to an old protocol existing already are mixed with new terminals adopting a new protocol that is made by modifying the old protocol. PRIOR ART DOCUMENT Non-Patent Document [Non-patent Document 1] “Field Wireless Solution Based on ISA100.11a to Innovate Instrumentation,” prepared by Shuji Yamamoto and other two, Yokogawa Technical Report, Yokogawa Electric Corporation, 2010, Vol. 53, No. 2 (2010), p. 7 to p. 12 [Non-patent Document 2] “World's First Wireless Field Instruments Based on ISA100.11a,” prepared by Shuji Yamamoto and other three, Yokogawa Technical Report, Yokogawa Electric Corporation, 2010, Vol. 53, No. 2 (2010), p. 13 to p. 16 Patent Document [Patent Document 1] JP-A-2008-154087 The above-mentioned wireless communication standard has been reviewed and revised as appropriate so as to be able to cope with technological advances and environmental changes, for example. As a result, it is conceivable in some cases that a wireless field device having been used from the beginning of the use of an existing process control system operates on the basis of the initial standard version ISA100.11a-2009, for example, but a wireless field device newly added to the existing process control system operates on the basis of the revised standard version ISA100.11a-2011 that is being revised. In incompatible and different standards, such as the initial standard version ISA100.11a-2009 and the revised standard version ISA100.11a-2011, the standards are different from each other in the following points: a) different in the parameter that is used for MIC calculation b) different in the parameter ID (Attribute ID) required when making an access to the parameter possessed by a field device c) different in the data structure of the parameter possessed by a field device Hence, field devices operating on the basis of the different standards cannot be mixedly connected. In this case, this can be solved by changing the firmware of all the existing field devices so that the devices operate on the basis of the revised standard ISA100.11a-2011. However, enormous cost is necessary to change the firmware of all the wireless field devices having been used from the beginning of the use of the existing process control system. Accordingly, it is desired that field devices operating on the basis of an existing standard and field devices operating on the basis of a revised new standard can be mixed in a process control system. SUMMARY Exemplary embodiments of the invention provide a wireless network system in which devices operating on the basis of an existing standard and devices operating on the basis of a revised new standard can be operated. A wireless network system according to an exemplary embodiment comprises: a plurality of devices operating on the basis of incompatible and different standards, wherein at least one of the devices comprises a standard identifying module configured to identify standards on the basis of parameters inherent and different in the respective standards. The standard identifying module may be configured to identify the standard on the basis of a calculation result of a manipulation detection code. The incompatible and different standards may correspond to the old version and the new version of the industrial automation wireless communication standard ISA100.11a. Consequently, the plurality of devices operating on the basis of the incompatible and different standards and mixedly connected to the same wireless network system can operate on the basis of the standards respectively identified. More specifically, in the case that field devices operating on the basis of a revised new standard are provided with, for example, a manipulation detection code calculation function operating on the basis of both the existing standard and the revised new standard, the devices operating on the basis of the existing standard can be mixed with the devices operating on the basis of the revised new standard in the same wireless network system. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing a processor 30 on a receiving side in a device operating on a new version standard according to an exemplary embodiment of the present invention. FIG. 2 is a flowchart illustrating a flow of MIC processing at the time when data is received in the processor 30 shown in FIG. 1 . FIGS. 3A to 3C are data structure diagrams on the basis of an industrial automation wireless communication standard ISA100.11a. FIG. 4 is a configuration explanatory view showing a wireless network system in the related art. FIG. 5 is a block diagram showing a processor 20 on the receiving side in the related art. FIG. 6 is a flowchart illustrating a flow of MIC processing at the time when data is received in the processor 20 shown in FIG. 5 . DETAILED DESCRIPTION An embodiment access to the present invention will be described below in detail using the drawings. FIG. 1 is a block diagram showing an example of a processor 30 on the receiving side in a device operating on a new version standard and to be used in the present invention. FIG. 2 is a flowchart illustrating an example of the flow of MIC processing at the time when data is received in the processor 30 on the receiving side shown in FIG. 1 . FIGS. 3A to 3C are data structures diagrams on the basis of the industrial automation wireless communication standard ISA100.11a. The processor 30 on the receiving side in the device operating on the basis of the new version standard and to be used in the present invention is provided with both an old version MIC calculator 35 a and a new version MIC calculator 35 b. Referring to FIGS. 1 and 2 , when a data receiver 31 receives data transmitted from the transmitting side (at step S 1 ), an MIC detector 32 detects the MIC that was calculated and added to the data on the transmitting side (at step S 2 ). On the other hand, from the structure of the data shown in FIG. 3A and received by the data receiver 21 , a standard version identifier detector 33 detects the identifier representing the version of the wireless communication standard on the basis of which the received data is generated (at step S 3 ). On the basis of the identifier detected by the standard version identifier detector 33 , a standard version judgment section 34 judges whether the version of the standard is old (at step S 4 ). FIG. 3A is a view showing the structure of a data frame DPDU (Datalink Protocol Data Unit) to be transmitted and received between devices at the DL levels (datalink layer levels) thereof. FIG. 3B is a view showing the structure of the DHDR frame of the revised standard version ISA100.11a-2011, and FIG. 3C is a view showing the structure of the DHDR frame of the initial standard version ISA100.11a-2009. Targets to be authenticated by DMIC are MICR, DHR and DSDU (DL Service Unit) as shown in FIG. 3A . DHR is the header of DPDU and is composed of DHDR, DMXHR, DAUX, DROUT and DADOR. The identifier of the standard version (DL Version) of the industrial automation wireless communication standard ISA100.11a is included in the frame of DHDR. In other words, the value of the revised standard version ISA100.11a-2011 is “01” as shown in FIG. 3B , and the value of the initial standard version ISA100.11a-2009 is “00” as shown in FIG. 3C . Referring again to FIGS. 1 and 2 , in the case that the standard version judgment section 34 judges that the version is old, the old version MIC calculator 35 a calculates an MIC on the basis of the algorithm of the old version including a cipher key common to the transmitting side (at step S 5 ). An MIC comparator 36 compares and checks the MIC detected by the MIC detector 32 with the MIC calculated by the old version MIC calculator 35 a , thereby judging whether the two are coincident with each other (at step S 6 ). In the case that the two are coincident with each other, the MIC calculated by the old version MIC calculator 35 a is added to an acknowledge signal ACK generated by an ACK generator 37 and then transmitted to the transmitting side via a data transmitter 39 (at step S 7 ). On the other hand, in the case that the two are not coincident with each other, the MIC calculated by the old version MIC calculator 35 a is added to a non-acknowledge signal NACK generated by an NACK generator 38 and then transmitted to the transmitting side via the data transmitter 39 (at step S 8 ). In contrast, in the case that the standard version judgment section 34 judges that the version is new, the new version MIC calculator 35 b calculates an MIC on the basis of the algorithm of the new version including a cipher key common to the transmitting side (at step S 9 ). The MIC comparator 36 compares and checks the MIC detected by the MIC detector 32 with the MIC calculated by the new version MIC calculator 35 b , thereby judging whether the two are coincident with each other (at step S 10 ). In the case that the two are coincident with each other, the MIC calculated by the new version MIC calculator 35 b is added to an acknowledge signal ACK generated by the ACK generator 37 and then transmitted to the transmitting side via the data transmitter 39 (at step S 11 ). On the other hand, in the case that the two are not coincident with each other, the MIC calculated by the new version MIC calculator 35 b is added to a non-acknowledge signal NACK generated by the NACK generator 38 and then transmitted to the transmitting side via the data transmitter 39 (at step S 12 ). With this configuration, the devices operating on the basis of the existing standard can be mixed with the devices operating on the revised new standard in the same wireless network system. In the above-mentioned embodiment, the standard version (DL version) identifier is used as means for identifying the version of the standard when the MIC calculation processing is performed. However, in the case that, for example, a numerical value in data is different depending on the standard, it is not limited to use the standard version identifier, but either may be used. Furthermore, in the case that transmission is performed by a communication partner from an device conforming to a new standard and if the version of the standard is unknown, it may be possible to judge the version of the standard used by the communication partner on the basis of ACK/NACK retuned from the communication partner after the transmission of the result of the calculation on the basis of the MIC algorithm of either one of the versions of the standard. After the judgment, it may be possible that the pair of the identifier of the device and the version of the standard is stored, that the predetermined version of the standard is selected depending on the identifier of the device, and that an MIC is calculated on the basis of the algorithm of the selected version. Moreover, in the case that Attribute ID is determined when an access is made to a parameter having Attribute ID being different depending on the version of the standard, it may be possible to use the version identification method used in the MIC processing. Still further, it may be possible that a parameter being different in each version of the standard is read beforehand and that the version of the standard is identified by the content of the response so that operation is performed accordingly. As described above, the present invention can realize a wireless network system in which devices operating on the basis of an existing standard and devices operating on the basis of a revised new standard can operate in the same system. In particular, the present invention is effective in the case that devices operating on the basis of a new standard are used in a process control system structured by an existing wireless network system in industrial automation.
A wireless network system includes a plurality of devices operating on the basis of incompatible and different standards. At least one of the devices comprises a standard identifying module configured to identify standards on the basis of parameters inherent and different in the respective standards.
7
This application claims the benefit of U.S. provisional Application Ser. No. 60/012,626, filed Mar. 01, 1996. BACKGROUND OF THE INVENTION The present invention relates to recreational boards, such as a snowboard, and more particularly to a an adjustable boot-binding mount with a quick release mechanism that can be attached to a recreational board for facilitating the attachment, adjustment and use of a conventional boot binding or boot with the recreational board. A snowboard is a single board, generally wider and shorter than a snow ski, on which a rider ("snowboarder") rides down a snow-covered inclined surface. The popularity of snowboarding as a recreational sport has increased dramatically in recent years, with snowboarders generally using the same facilities and resorts that skiers use throughout the world. In order to "ride" a snowboard, a user must bind his feet to the snowboard in some manner. Several different types of binding systems are known in the art, as represented, e.g., by the binding systems shown in U.S. Pat. Nos. 5,354,088; 5,236,216; 5,190,311; 5,044,654; 4,964,649; 4,871,337. Commercially-available boot bindings have also been developed in recent years for this purpose. Such bindings may be purchased from, e.g., Burton Inc. of Burlington, Vt. In use, the commercially-available boot binding is typically screwed or bolted to a top surface of the snowboard using a multiplicity of threaded mounting holes arranged in a prescribed pattern on the manufactured snowboard. Two boot bindings are thus mounted, one for each leg of the user. The relative longitudinal position of the boot bindings on the snowboard is usually adjustable within certain limits by selecting a different group of holes from the pattern of available mounting holes. Snowboard boot bindings, once mounted to the snowboard, typically include a second adjustment which allows the user (i.e., the "rider") to adjust the relative angular position of the boot binding to the longitudinal axis of the snowboard, thereby allowing the user to set the bindings to a position most comfortable to him or her as he or she rides the snowboard down a snow-covered incline. For example, if a user likes to ride with his/her left leg forward on the snowboard, then the boot binding will typically be adjusted so that the user's foot (toes) point to the user's right relative to the longitudinal axis of the snowboard. Similarly, if a user rides with his/her right leg forward, the boot binding will usually be adjusted so that the toes point to the user's left. The amount of the second adjustment, hereafter referred to as the angular adjustment of the boot binding, varies greatly as a function of individual preference. Disadvantageously, the second adjustment, i.e., the angular adjustment of the boot binding, is not easily made, as least not when the most common commercially-available snowboard boot bindings are used. Rather, the user must typically dismount, i.e., take his or her boot out of the boot binding; unlock or disengage a plate on which the boot mounts, e.g., by loosening a screw or other capturing mechanism using a special tool; readjust the plate to a new angular position; lock or reengage the plate in its new position; and then remount, i.e., place his or her boot back into the boot binding. Unfortunately, the above-described adjustment process--of dismounting, unlocking, adjusting, locking, and remounting--is extremely cumbersome and time-consuming to perform, particularly while on the snowboarding slope or at the snowboarding site. Because this adjustment is not easily made, many users, once the adjustment has initially been performed to their liking, refuse to make any further adjustments. Such non-adjustment may result in some rather difficult situations while snowboarding. For example, when the user is waiting in a lift line, he or she may have to "hop" in an awkward fashion, with the snowboard skewed at an awkward angle relative to his or her feet and the other individuals waiting in line, many of whom are skiers. Alternatively, the snowboarder, while waiting in a lift line, may disengage one boot from one of the snowboard boot bindings, but leave the other foot engaged to the other snowboard boot binding such that either the snowboard protrudes out from the engaged foot at an awkward angle, or he/she must maintain his foot at an awkward and uncomfortable angle. Similarly, when riding in a lift chair, the snowboard (if not completely removed from the user and hung from the back of the lift chair) typically dangles from at least one foot at an awkward angle, which awkward angle is not only uncomfortable to the snowboarder, but also may be bothersome to other lift riders. One type of quick-action adjustable snow boot binding mounting known in the art is disclosed in U.S. Pat. No. 5,028,068, issued to Donovan. The binding mount described in the '068 patent includes an adapter plate for gluing, bolting, or otherwise fastening the adaptor plate to a snowboard top. A swivel plate is then pivotally mounted on top of the adaptor plate by a center bearing and flexible bushings (to allow flexation of the swivel plate) and a through-bolt (which serves as an axle, or pivot point for the swivel plate). The swivel plate is thus free to rotate a full 360 degrees about the pivot point. A cable extends around a circumferential edge of the swivel plate, and may be selectively tightened through the use of a conventional pull arm and handle, thereby applying a circumferential locking force around the edge of the swivel plate. Such arrangement is potentially dangerous because the pull arm and handle must be latched in its down position in order for locking to occur. A user may forget such latch down, or may attempt but not achieve latch down, in which case the swivel plate is left loose to spin freely (a very undesirable and unsafe condition). Further, the handle may pop up while the snowboard is in use, thus also unlocking the swivel plate so that it rotates at a time when the user does not want it to rotate. Hence, it is apparent that an automatic locking mechanism is needed --one that always remains locked except when the user is applying a positive manual force to achieve an unlocked position. Further, because the swivel plate extends up above the board surface, so the locking cable may be wrapped around it, snow and ice can easily become packed under the swivel plate, causing difficulties in making adjustments. It is thus evident that improvements are needed in the manner in which angular or rotational adjustments are made to boot bindings mounted on a snowboard. SUMMARY OF THE INVENTION The present invention addresses the above and other needs by providing a lockable and rotatable boot-binding mount which is affixed directly to the top surface of a snowboard (or other recreational board) without the use of a locking cable or through-bolt axle, as is used, e.g., in the above-referenced '068 patent. The adjustable (i.e., "lockable" and "rotatable") boot-binding mount of the present invention includes a rotatable mounting plate mounted close to the surface of the recreational board. The adjustable mounting plate has means thereon for directly attaching a conventional or custom snowboard boot binding or boot thereto without flexation. Such arrangement advantageously affords the user more direct control of the snowboard as it is being ridden than has heretofore been available using prior art adjustable mounts. In use, the user unlocks the rotatable mounting plate by pulling and holding a single release handle, adjusts the angular position of the mounting plate (and boot binding or boot attached thereto) to a desired position by, e.g., simply twisting or rotating his or her foot while the mounting plate is unlocked, and then releases the release handle, thereby securely locking the mounting plate in the new position. Thus, the user is able to quickly and easily make whatever angular adjustments are needed or are appropriate for the boot binding mount regardless of whether the user is waiting in a lift line, riding a lift, or snowboarding down a slope. The lockable and rotatable boot-binding mount of the present invention comprises a rotatable mounting plate (sometimes referred to herein as a "swivel plate") which has threaded mounting holes therein to which a conventional (or custom) boot binding or boot may be directly attached. The mounting plate is rotatably retained within a circular cutout or recess of a base plate. The base plate, in turn, is securely fastened to the top surface of the snowboard or other ridable board. In accordance with one aspect of the invention, the base plate may be mounted directly to the snowboard using the same mounting holes as would otherwise be used for direct mounting of a boot binding to the snowboard. During normal use, the rotatable mounting plate is locked in position within the base plate by a spring-loaded locking mechanism which radially directs a locking arm into the rotatable mounting plate to prevent it from rotating, thereby firmly maintaining the rotatable mounting plate (and boot binding attached thereto) in a desired angular position. When an adjustment is needed, e.g., while standing in lift lines, riding a lift, or switching from a left-leg-forward position to a right-leg-forward position, a quick release mechanism releases the spring-loaded locking mechanism (i.e., retracts the locking arm) so that a different angular position of the rotatable mounting plate (and hence of the boot binding) may be quickly and easily realized. Once the desired angular position of the rotatable mounting plate has been achieved, then the locking mechanism is released, causing the rotatable mounting plate (and hence the boot binding) to be firmly locked in its new angular position. The present invention may be broadly characterized as an adjustable boot-binding mount for use with a recreational board, such as a snow board, where the boot-binding mount includes four main elements: (1) a base plate; (2) means for mounting the base plate to a top surface of the recreational board; (3) a swivel (or mounting) plate mounted for rotation to the base plate, and (4) releasable locking means for radially applying a locking force to the swivel plate which prevents the swivel plate from rotating. The swivel plate has boot-binding attachment means thereon for securely mounting a boot binding thereto, whereby rotation of the swivel plate effectuates a rotation of any boot binding mounted to the swivel plate. It is a feature of the invention to provide a rotatable-boot-binding mount for use with a snowboard, or similar recreational board, that can be quickly, easily and securely rotated to a desired angular orientation on the top surface of the snowboard. It is another feature of the invention to provide such a rotatable-boot-binding mount wherein the rotational adjustments may be made over a full 360 degrees in small increments, e.g., six degrees or less. It is an additional feature of the invention to provide a rotatable-boot-binding mount that can be easy installed on a snowboard, or other recreational board, without disassembly and reassembly of its various components. It is yet a further feature of the invention to provide a rotatable-boot-binding mount for use with a snowboard or the like that is automatically securely and reliably locked in a set angular position, yet may be quickly and easily unlocked temporarily so that a new angular position may be set. It is still another feature of the invention, in accordance with one aspect thereof, to provide a rotatable-boot-binding mount for use with a recreational board, such as a snowboard, wherein a swivel plate (or rotatable mounting plate) used with the mount remains close to the snowboard surface and does not have to extend above the surface of the snowboard in order to permit adjustment and/or locking of the plate in a new position. BRIEF DESCRIPTION OF THE DRAWINGS The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein: FIG. 1 is an exploded view that depicts the manner in which at least one rotatable-boot-binding mount is attached to a snowboard in accordance with the present invention; FIG. 2 is an exploded view of preferred embodiment of the rotatable-boot-binding mount of the invention; FIG. 3 is a partial side sectional view of the rotatable boot-binding mount of FIG. 2; FIG. 4 is an enlarged cut-a-way top view of a portion of the rotatable boot-binding mount, showing details of the releasable locking mechanism used therewith; and FIG. 5 is a top, partially cut-a-way, view of the rotatable boot-binding mount of FIG. 2. Corresponding reference characters indicate corresponding components throughout the several views of the drawings. DETAILED DESCRIPTION OF THE INVENTION The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims. Turning first to FIG. 1, an exploded view is shown that depicts the manner in which a pair of adjustable boot-binding mounts 20 made in accordance with the present invention may be attached to a recreational board 10, such as a snowboard. The board 10 typically includes a set of mounting holes 14 arranged in a particular mounting pattern 12. The holes 14 are usually threaded mounting holes adapted to receive a screw or bolt (not shown) that passes through a mounting hole of the mount 20. In the absence of the present invention, a conventional boot binding 60, adapted to hold a boot 62 of a snowboard user 64, is mounted directly to the set of mounting holes 12 located on an upper surface of the snowboard 10. Such direct mounting advantageously affords the user 64 excellent control of the snowboard 10 as it is being ridden. Unfortunately, however, such direct mounting makes it very difficult to easily adjust the angular position of the bindings 60 relative to a longitudinal axis 16 of the snowboard 10, as previously discussed. The present invention comprises an adjustable boot-binding mount 20 which can be easily mounted to the top surface of the snowboard 10 using the standard mounting holes 14 typically found on a snowboard. In the event that mounting holes 14 do not exist on the snowboard 10 to which the boot-binding mounts 20 of the present invention are to be attached, then such holes 14 can be easily added to the board 10. Alternatively, other attachment means (e.g., gluing, bonding, etc.) as are known in the art may be used to secure the mounts 20 to the board. Once the boot-binding mounts 20 have been attached to the snowboard 10, a conventional boot binding 60 is attached to the mount. To facilitate such attachment, each mount 20 includes a pattern 24 of individual mounting holes 24 thereon that typically matches the pattern 12 of mounting holes 14 commonly found on most snowboards. Hence, it is a relatively easy task to simply screw or bolt the boot-binding 60 to the appropriate mounting holes 24 of the boot-binding mount 20. With the boot-binding 60 attached to the boot-binding mount 20, rotational or angular adjustment of the binding 60 relative to the snowboard 10 is easily performed, as explained more fully below, by simply pulling on a release handle 26 which forms part of the mount 20. With the handle 26 pulled back to a release position, the boot-binding 60, and hence the boot 62, may be rotated a full 360 degrees by, e.g., simply having the user twist his or her foot. Once the desired angular position has been reached, then the handle 26 is released, causing the boot-binding 60 to be locked to within a small incremental amount, e.g., ±3 degrees, of the new angular position until the next adjustment is made. It should be noted that, as shown in FIG. 1, two boot-binding mounts 20 are used, one for each foot and boot-binding 60 of the user 62. For many users, only the front mount 20 need be adjustable and lockable in accordance with the teachings of the present invention. That is, for such users, the back mount 20, once set to a given angular position, need not be changed. For other users, however, easy adjustment and locking of both the front and rear mounts 20 is desired, e.g., so that the user can easily switch between a left-foot-forward position to a right-foot-forward position. As seen in FIG. 1, the mounts 20 are typically secured to the board 10 so that one is in a forward position and one is in a rearward position, with the mounts 20 being mounted on the board 10 so as to be aligned with the longitudinal axis 16 of the board 10 (although such alignment is not necessary for purposes of the present invention). The present invention assumes that at least one of the mounts 20, e.g., the forward mount, is adjustable and lockable as taught herein. The description of the invention that follows will thus be directed to a single boot-binding mount 20 because at least one such boot-binding mount must always be used. Further, it should be noted that while FIG. 1 shows a boot 62 of a user 64 being mounted in a boot-binding 60 which, in turn, is mounted to the adjustable boot-binding mount 20 of the present invention, it is contemplated that the adjustable mount 20 may also be used directly with a special boot that mounts directly to the adjustable mount 20 without the need for a separate boot-binder 60. Indeed, the present invention is directed to the adjustable mount 20, regardless of the type of recreational board 10, or boot-binder 60, and/or boot 62, that may be attached thereto. Referring next to FIGS. 2-5, there are shown various views of a preferred embodiment of the adjustable boot-binding mount 20 of the present invention. FIG. 2 is perhaps the most instructive of these figures as it shows an exploded view of all the parts that are used within the adjustable mount 20. In describing these parts with reference to FIG. 2, reference will also be made to others of the figures so that the parts may be seen in their assembled form. As seen in FIG. 2, the adjustable boot-binding mount 20 includes four main components: a base plate 30, a swivel plate 40 (also referred to as a rotating mounting plate 40 or simply a rotating plate 40), a retaining ring 44, and a sliding arm 27. The base plate 30 has a circular recess 39 therein having an inside diameter just slightly larger than the diameter of the swivel plate 40. Hence, the swivel plate 40 can be positioned inside of the circular recess 39 and freely rotate, although significant longitudinal or lateral movement of the plate 40 is restrained (where longitudinal movement is movement in a direction along the longitudinal axis 16, lateral movement is movement in a direction perpendicular to the longitudinal axis). Note that rotational movement of the swivel plate 40 is not dependent upon a pivot point or axle to which the plate 40 is attached at its center. Rather, the plate 40 simply may turn or rotate within the recess 39. A rim 31, which comprises an integral part of the base plate 30, surrounds the recess 39. A retaining ring 44 is secured to the rim 31 by screws 46 or equivalent fasteners which are received in holes 47. The retaining ring 44 has an inside diameter less than the diameter of the swivel plate 40, and thus keeps the swivel plate 40 within the recess 39. In some embodiments, the retaining ring 44 may comprise an integral part of the rim 39 and base plate 30, and may not even be a ring, but may rather comprise tabs or fingers that extend over (or into a slot of) the swivel plate 40 so as to keep the plate 40 in its desired position within the circular recess of the base plate 30. Any suitable "keeper" means may be used for this purpose. The swivel plate 40 has a pattern 22 of mounting holes 24 thereon which, in the preferred embodiment, matches the same hole pattern 12 that is typically found on a snowboard or other recreational board to which a boot-binding 60 (FIG. 1) is to be mounted. The mounting holes 24 are typically realized by placing threaded inserts into the plate 40 arranged in the desired pattern. A key element of the present invention is the locking mechanism which is used to prevent rotation of the swivel plate 40. Such locking mechanism involves the use of a slidable arm 27 that is axially or radially forced into the perimeter of the swivel plate 40 by a radial or axial force created by coiled spring 48. (Note, as used herein, "radial" either or axial refers to a direction generally aligned with a center point of the swivel plate 40.) Locking is further secured by the use of locking teeth 42 spaced equally around the perimeter of the swivel plate 40 and corresponding engaging teeth 43 located on one end or tip of the slidable arm 27. Thus, when the slidable arm 27 is radially forced into an engagement position, as shown best in FIG. 4, and also evident from FIG. 5, the locking teeth 42 and engaging teeth 43 mesh, or engage, and rotational movement of the swivel plate 40 is prevented. However, when the slidable arm 27 is radially pulled back from the engagement position, the swivel plate 40 is free to rotate, or free to be adjusted to any desirable angular position, and then locked in the new angular position to within the angular tolerance defined by the locking teeth 42. While any number of locking teeth 42 may be used on the swivel plate 40, a preferred number of teeth is 60. With n locking teeth 42 spaced around the entire circumference of the plate 40, the swivel plate 40 may be locked in discrete angular increments of 360/n degrees. Thus, with 60 teeth, the locked angular adjustment increment of the swivel plate 40 is 6 degrees. Some embodiments of the invention may use locking teeth around only a desired segment of the plate 40 when it is known that angular adjustment is not needed nor desired for a full 360 degrees. Further, while the locking teeth 42 are shown in the figures as being positioned around the circumferential edge of the swivel plate 40, such circumferential teeth 42 may serve their intended function without being at the very edge of the plate 40, i.e., they may be located inward from the circumferential edge of the plate 40 at an inner radius which is less than the radius of the plate 40. As seen best in FIGS. 4 or 5, the slidable arm includes three engaging teeth 43 which mesh with four locking teeth 42. More or less engaging teeth may be used, as desired. One engaging tooth is all that is required to perform the locking function. It should be noted that other embodiments of the invention may use locking mechanisms that use other engaging elements other than teeth. For example, holes may be inserted around a periphery edge of the swivel plate 40 into which a pin(s) may be radially inserted when locking is desired. As seen best in FIG. 2, the slidable arm 27 is positioned within a channel 29 which is formed within the base plate 30. The arm 27 has the engaging teeth 43 at one end thereof. The other end of the arm 27 is bent up to form a handle 26. When the arm 27 is placed in the base plate channel 29, a spring 48 is also inserted into the channel 29, and more particularly positioned within a slot 23 of the arm 27. The spring is then placed in compression, with one end of the compressed spring 48 being set against a retaining surface within the channel 29, and the other end of the compressed spring being positioned to contact an end of the slot 23 of the arm 27. Thus, the force created by the compressed spring radially forces the arm 27 into its engaging position with the swivel plate 40, thereby locking the plate 40 and preventing rotation thereof. A manual force applied to the handle 26 overcomes the spring force and allows the arm to be slid back out of its engaging position, thereby freeing up the swivel plate 40 for rotation. A cover plate 50 covers the channel 29, and holds the arm 27 and spring 48 in their appropriate positions within the channel 29. The cover plate is secured to the base plate 30 using screws 52, or equivalent fasteners, received into base-plate holes 53. Any suitable means may be employed to attach the base plate 30 to the top surface of the snowboard 10 providing such attachment means do not interfere with the rotation or locking of the swivel plate 40. For example, suitable holes placed in the bottom of the recess 39 of the base plate 30, counterbored as required to allow heads of the screws or bolts to be positioned below a bottom surface of the recess 39, could be used. A preferred means of attachment for the base plate 30, especially when the base plate 30 is made from plastic, is to make an opening 32 in the bottom of the recess 39, which opening is generally of sufficient size to fully expose the mounting hole pattern 12 of the snowboard 10. The opening 32 has a recessed shoulder 34 around its perimeter. A mounting or attachments plate 36, typically a die-cut, stamped, metal plate of a size designed to fit within the opening 32, has holes 38 in a bottom surface therethrough arranged in a pattern which is compatible with the hole pattern 12 found on the surface of the snowboard 10. The mounting plate 36 also has a ridge 37 around its perimeter designed to rest upon the shoulder 34 surrounding the opening 32. (See FIGS. 3 and 5.) As seen in FIG. 3, the bottom surface of the mounting plate 36 rests upon the surface of the board 10 at the same time that the ridge 37 rests on the shoulder 34. Thus, by securing the bottom surface of the attachment plate 36 to the snowboard 10 by inserting bolts or screws (not shown) through the holes 38 of the attachment plate 36 into the mounting holes 14 of the snowboard 10, the entire base plate 30 is tightly secured or fastened to the snowboard 10. Moreover, as seen in FIG. 3, because the mounting or attachment plate 36 is typically a stamped metal part, shaped like a trough, or a rectangular cake pan, with its mounting or bottom surface being below the ridge 37 which engages the shoulder 34 of the opening 32, a void or space 35 is created within the opening 32 where the heads of the bolts or screws used to fasten the attachment plate 36 to the board 10 may reside without interfering with the rotation of the swivel plate 40. Use of the mounting or attachment plate 36, as described above, facilitates the mounting of the base plate 30 particularly when the base plate 30 is made from a thin, light-weight, material, e.g., plastic, which may not be conducive to having counterbored holes placed therethrough. Also, such plate 36 allows a wide variety of different types of recreational boards 10 using different hole patterns to be used. As different hole patterns are encountered, a different attachment plate 36 may be provided which includes a new or different hole pattern without having to alter or modify other components of the adjustable boot-binding mount 20, thereby keeping manufacturing and retro-fitting expenses at a minimum. Further, it is noted that by providing a hole pattern in the attachment plate 36 that includes seven holes, as shown in FIG. 2, most of the commonly used hole patterns currently found on snowboards, and currently used with most commercially known boot-bindings, will be alignable with at least three of the holes of the seven hole pattern. To further facilitate attachment of the base plate 30 to the board 10 without having to disassemble the boot-binding mount 20 (i.e., without having to remove the retaining ring 44 and the swivel plate 40), an access slot 45 is provided through the plate 40. Such access slot 45 selectively provides access from the top side of the mount 20 to each of the holes 38 of the attachment plate 36 as the swivel plate 40 is rotated. Thus, when the mount is mounted to the board 10, a conventional wrench, nut driver, or other suitable tool may be readily used through the access slot 45, rotating the swivel plate as needed to expose the desired hole 38, to secure and tighten each of the bolts or screws which are used to attach the attachment plate 36 to the board 10. A removable access cover plate 54 may also be used, as desired, to cover or close the access slot 45 once the mounting has been completed. An advantage of the present invention, as best seen in the side-sectional view of FIG. 3, is that the swivel plate 40 is located close to the surface of the snowboard 10, thus approximating the same feeling and control that a user achieves when the boot-binding 60 (FIG. 1) is mounted directly to the board 10. (Note, the retaining ring 44 has been omitted from FIG. 3.) In general, the parts of the adjustable boot-binding mount 20 of the invention described above in connection with FIGS. 2-5 may be made from many different types of materials, including many different types of metals (e..g, aluminum or aluminum alloys), plastics, rubber, ceramics and/or other synthetic/composite materials. As an additional advantage of the invention, all of its parts, e.g., the base plate 30, the swivel plate 40, retaining ring 44, slidable arm 27, cover 50, attachment plate 36, etc., do not have to be machined parts that require a precision fit one with another in order for the invention to perform its intended and desired function. Tolerances on the order of ±0.03125 inches (±1/32 of an inch), for example, may readily be accommodated for these parts without degrading in any way the operation of the adjustable mount. Such tolerances can readily be achieved without machining using conventional molding, stamping, and/or die cut metal techniques, as is known in the art. Such construction allows the cost of making the invention to be kept relatively low. As described above, it is thus seen that the invention provides a adjustable boot-binding mount for use with a snowboard, or similar recreational board, that can be quickly, easily and securely rotated, over a full 360 degree range, to a desired orientation on the top surface of the snowboard. It is further seen that the invention provides an adjustable boot-binding mount that can be inexpensively manufactured, and that may be easy installed on a snowboard, or other recreational board, without disassembly and reassembly of its various components. While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
An adjustable, rotatable boot-binding mount (20) includes a swivel plate (40) having threaded mounting holes (24) therein to which a conventional boot binding (60) or boot may be mounted. The swivel plate (40) is rotatably retained within a base plate (30) which is securely fastened to the top surface of a snowboard (10) or other recreational board. During normal use, the swivel plate (40) is automatically and continuously locked against rotation within the base plate (30), thereby securely maintaining the boot binding in a desired angular position relative to the snowboard. At other times, e.g., while standing in lift lines or riding a lift, a quick release mechanism (27, 48) allows the swivel plate to be temporarily unlocked so that a different angular position of the swivel plate (and hence a different angular position of the boot binding or boot) relative to the snowboard may be quickly and easily realized.
0
FIELD OF THE INVENTION The invention relates to a ball bearing cage that is formed from two ring elements that are set axially on each other and are produced as shaped sheet metal parts. These two ring elements together form connecting sections arranged in the circumferential direction, as well as ball guide pockets lying in-between. Balls are held in the ball guide pockets in the installed state of the ball bearing cage and guided in this way in the running grooves of a bearing inner ring and a bearing outer ring. Furthermore, the invention also relates to a grooved ball bearing that is equipped as such with a ball bearing cage by which the balls are guided and in this way kept at a distance in the circumferential direction. BACKGROUND From DE 925 203 A a ball bearing cage of the construction noted above is known. The two cage halves are here riveted in the area of connecting sections or connected to each other by a special connecting structure formed by the cage halves. From DE 39 39 438 A1 a ball bearing cage for a grooved ball bearing is likewise known that is assembled from two ring elements. The ring elements are shaped so that the ball guide pockets formed therein have a non-round contour in a top view of a ball guide pocket. Finally, from DE 36 40 633 A1 another ball bearing cage assembled from two ring elements for a grooved ball bearing is known in which the contact plane between the two ring elements is offset in the axial direction relative to a ball center plane defined by the ball pocket centers. Sheet metal cages with inner, spherically concave pockets (ball-shaped pockets) are used to a great extent in grooved ball bearings. The cage is here typically made from two ring-shaped cage halves that are assembled in the axial direction and can be connected to each other in different ways (e.g., riveted cages, tabbed cages, and welded cages). The balls are here guided into the functional position (installed in the bearing) by the cage in the ball-shaped pockets. Here, care must be taken that the cage remains guided by a roller body, i.e., the cage does not contact the bearing rings. The roller body guide or the radial play is defined by the ring domed geometry of each ball guide pocket. The design/definition of the unsupported ball span is typically tailored to the ideal geometry. The radial clearance is here defined by the diameter of the cage pocket at the cage outer edges. Sheet metal cages of this construction are produced by punching (cutting). Thus, all of the punching surfaces on one side have a punch entry and on the other side a punch outlet/punching burr. In order to not disrupt the movement of the ball (noise, friction), the punching direction is normally selected so that the punch entry is on the inside of the ball pocket. Because the sheet metal is also thicker with increasing ball diameter, the dimension of the punch entry also increases. Consequently, the unsupported ball span is large and the cage can run, under some circumstances, on the bearing ring. SUMMARY The invention is based on the objective of providing a ball bearing cage for a grooved ball bearing, wherein this cage can be produced economically and is distinguished by an advantageous mechanical operating behavior. This objective is met according to the invention by a ball bearing cage with: a first ring element that is produced as a shaped sheet metal part and has axial bulges arranged in the circumferential direction and separated from each other by seating surfaces, a second ring element that is likewise produced as a shaped sheet metal part and likewise has axial bulges arranged in the circumferential direction and separated by seating surfaces, and ball guide pockets that are formed via the joining of the seating surfaces of the two ring elements between the bordering bulge inner walls, each for holding a ball, wherein the ring elements are formed such that each of the bulging inner walls bordering the ball guide pockets form a concave groove cross section relative to the ball and the groove cross section has a recessed construction in an inner area lying between these inner and outer ball contact zones such that a gap remains between the cage and its inner area and thus the ball does not contact the inner area. In this way it is advantageously possible to create a ball bearing cage in which the contact points of each ball with the cage are shifted in the direction of the pocket center. In this way, advantageously the effect of the so-called punch entry on the radial freedom of movement of each ball in the cage pocket allocated to it is reduced, in particular, the punch entry no longer has an effect on the unsupported ball span. In addition, it is advantageously possible by this construction to reduce the contact surfaces of the ball in the cage pocket relative to conventional cage constructions. Advantageously, the friction moment generated by frictional forces between the ball and cage is reduced accordingly. The groove cross section is advantageously constructed such that the ball contact zones include, to the inner or outer edge of the ring elements, a radial distance of at least the ring width and the balls cannot contact the edge area of the ring elements thus lying outside of the ball contact zones. In the ball bearing cage according to the invention, the cage pocket has, in cross section, a “roof shape” at least in certain peripheral zones. The contact points between the ball and cage still lie significantly within the inner geometry of the cage pocket. The concept according to the invention is suitable, in particular, for grooved ball bearings with larger dimensions. The invention is essentially directed at the design of a ball cage made from sheet steel for grooved ball bearings. The invention can be used both in the industrial and also automotive sectors. The shape of the cage pocket is shaped according to the invention such that the radial clearance (unsupported ball span) of the ball is determined by an area of the ring elements influenced less pronouncedly by the edge geometry of the ring elements and thus can be exactly defined and maintained. According to one especially preferred embodiment of the invention, the ball bearing cage is constructed such that the inner ball contact zone is formed by a locally straight inner wall section in axial section. Advantageously, the outer ball contact zone is also formed by a locally straight outer wall section in axial section. This construction advantageously produces lubricant gap geometries that support the establishment of a lubricating film between the cage and ball. These two wall sections are set at an obtuse angle relative to each other. The transition area connecting these two wall sections, i.e., the valley or groove base, does not contact the ball, but instead forms a gap for the ball when the ball contacts the ball contact zones. The grooved ball bearing cage according to the invention is advantageously constructed such that the two straight inner and outer wall sections in axial section are connected by a grooved base section and there is a curvature in this grooved base section whose radius is smaller than the ball radius. The ball guide pockets can be constructed here so that these surround each ball with minimal play, producing minimal freedom of movement for the ball in the radial direction. The ring elements are advantageously produced as punching shaped parts. It is also possible to produce the ring elements from a tape material and either to connect the joints or to place them when joining the ring elements so that the joints of a ring element are bridged by the other ring element. The two ring elements are connected advantageously by riveting the two ring elements in the area of the seating surfaces. As an alternative, it is also possible to connect the ring elements through welding, soldering, or in some other way through suitable geometric structures. Advantageously the radial width of the ring elements is approximately 40% to 55%, in particular 44% of the ball diameter in the area of the ball guide pockets. The radial freedom of movement of the ball in the ball guide pocket is advantageously in the range of 2% to 12% of the ball diameter. The radial distance of the inner limits of the ball contact zones is advantageously in the area of 20% to 30% of the radial width of the ring elements. The distance of the outer limits of the two ball contact zones is advantageously approximately 80% of the ring width. The ball bearing cage according to the invention is formed of two ring elements assembled in the axial direction. These form ball guide pockets in the assembled state. These ball guide pockets extend to a cylinder casing coaxial to the bearing axis and surround the balls equatorially. Essentially at the height of the circulating track of the ball centers, the geometry of the inner wall of the ball guide pockets is adjusted so that a crescent-shaped intermediate space in axial section is produced between the inner wall of the ball guide pocket and the surrounded ball. This open area is bounded by inner and outer ball contact zones. These inner and outer ball contact zones do not extend up to the inner and outer edge of the respective ring element, but instead maintain a certain distance to these elements. This distance is advantageously large enough that, in the area of the contact zones, there is no material deformation caused by punching of the ring elements, especially burrs. The invention is also essentially directed at a ball bearing cage that is formed from first and second ring elements, wherein these two ring elements form ball pockets arranged in the circumferential direction. Each of the bulging inner walls defining the ball guide pockets form an inner and an outer ball contact zone. The cross section of the ring elements in the area of the ball pockets is further constructed so that this forms an inner groove area lying between the inner and outer ball contact zones, so that a gap remains between the inner groove area and the ball when the ball contacts the ball contact zones. BRIEF DESCRIPTION OF THE DRAWINGS Additional details and features of the invention are given from the following description in connection with the drawings. Shown are: FIG. 1 an axial section detail for explaining a first embodiment of a grooved ball bearing that is equipped as such with a ball bearing cage according to the invention; FIG. 2 a perspective view of a ring element of the ball bearing cage according to FIG. 1 ; FIG. 3 a perspective detail for illustrating and explaining additional details of a ring element of a ball bearing cage according to the invention; FIG. 4A an axial section detail similar to FIG. 1 for illustrating a state in which an inner ball contact zone of the groove cross section of the ball bearing cage contacts the ball; FIG. 4B an axial section detail similar to FIG. 1 for illustrating a state in which an outer ball contact zone of the groove cross section of the ball bearing cage contacts the ball; FIG. 5A an axial section detail for illustrating another cage variant in a state in which an outer ball contact zone of the groove cross section of the ball bearing cage contacts the ball; FIG. 5B an axial section detail for illustrating the cage variant according to FIG. 5A in a state in which an inner ball contact zone of the groove cross section of the ball bearing cage contacts the ball; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In FIG. 1 , a grooved ball bearing is shown that is equipped with a ball bearing cage according to the invention. The grooved ball bearing comprises a bearing inner ring 1 , a bearing outer ring 2 , and balls 3 that are held in a ball track space defined between the two bearing rings 1 , 2 . The balls 3 are guided by the ball bearing cage according to the invention. This ball bearing cage is formed of a first ring element R 1 that is produced as a shaped sheet metal part and has axial bulges arranged in the circumferential direction and separated by seating surfaces. The ball bearing cage is further formed of a second ring element R 2 that is likewise produced as a shaped sheet metal part and likewise has axial bulges arranged in the circumferential direction and separated by seating surfaces. The two ring elements R 1 , R 2 are assembled so that these contact each other via their seating surfaces and also the bulges point in opposite directions. In this assembly state, the bulges form the ball guide pockets that can be seen here each for holding a ball 3 . The ball guide pockets form bulging inner walls W 1 , W 2 . These bulging inner walls obtain a special geometry according to the invention. Thus, the ring elements R 1 , R 2 are constructed in the area of the ball guide pockets so that each of the bulging inner walls W 1 , W 2 bordering the ball guide pockets forms a concave groove cross section for the ball 3 with inner and outer ball contact zones Ki, Ka. This produces a wall geometry that creates a two-zone guidance of the ball. Here, the cross section is adjusted so that it forms a groove cross section. This groove cross section is set deeper in a groove base or bottom area Rm between the inner and outer ball contact zones than the bulging of the ball 3 contacting the ball contact zone Ki, Ka. This produces a gap in the groove base or bottom area. The cross-sectional construction described here is directed toward cross sections of ring element material in sectional planes, in particular, sectional plane bundles that contain a radial axis through which the center of each ball guide pocket runs and here is perpendicular to the bearing axis. The ball guide pocket can be constructed so that the special groove cross section in the described sectional plane extends over the predominant part of the ball circumference. The cross-sectional shape can also be limited to certain peripheral zones, in particular, to those peripheral zones of the ball guide pocket that support the ball in the circumferential direction. The lateral flank areas can deviate from the geometry according to the invention. The narrow transition area directly on the ball center circulating path between the bulges and the ring seating surfaces can also have local geometry deviating from the disclosed geometry. As emerges especially from the detail view associated with FIG. 1 , in the embodiment shown here the groove cross section is contoured such that the inner ball contact zone Ki is formed by a straight inner wall section Wi in the axial section here. The outer contact zone is formed by a straight outer wall section Wa in axial section. The two straight inner and outer wall sections Wi, Wa in axial section are connected by a grooved base section Rm. In this groove base section Rm there is a curvature whose radius is smaller than half the ball diameter D. The ball bearing cage forms a “roof cross section” with locally straight contact zones Ki, Ka in cross section. The inner angle W 3 forms an obtuse angle of approximately 150°. The concavity of the cage between these contact zones Ki, Ka is greater than the convexity of the ball 5 , so that a gap zone is produced in the area of the groove base section Rm for the ball 5 . The outer limits of the ball contact zones adjacent to the ring edge are spaced apart from the ring edge so far that their position is not determined by production-dependent material deformation, in particular, differently formed edge burrs of the sheet metal material, and also these burrs cannot reach the ball 3 . The ball guide pocket shown here is constructed such that minimal freedom of movement for the ball in the radial direction can be defined extremely reliably but in a process-specific way. The ring elements R 1 , R 2 are produced as punching shaped parts and riveted in the area of the seating surfaces still addressed in connection with FIG. 2 . The radial width b of the ring elements R 1 , R 2 in the area of the ball guide pockets is approximately 40% to 50% of the ball diameter. In the embodiment shown here, the radial freedom of movement of the ball 3 in the ball guide pocket is in the range of 1% to 6% of half of the ball diameter D. The radial distance of the adjacent inner limits of the ball contact zones Ka, Ki is in the range of 60% to 80% of the ring width and in this actual example is at 69%. In FIG. 2 , the ring element R 2 of the ball bearing cage according to FIG. 1 is shown in the form of a perspective view. This ring element R 2 is produced as a shaped sheet metal part from sheet steel. The ring element R 2 forms several axial bulges P 2 arranged in the circumferential direction and separated by seating surfaces S 2 . The first ring element R 1 provided for the ball bearing cage according to FIG. 1 has a structurally identical construction. These two ring elements R 1 , R 2 are joined by the seating surfaces S 2 and riveted through the holes 4 that can be seen here. The composite part formed in this way forms ball guide pockets with a special shape—as already described with respect to FIG. 1 . In FIG. 1 , the cross section of the ring elements R 1 , R 2 in a section plane El was described that is defined as such by the bearing axis X and the ball pocket center Z of each ball guide pocket P 2 . The construction of the groove cross section according to the invention must not extend over the entire periphery of the ball guide pocket P 2 , that is, not over the entire length of the ball guide belt. Advantageously, however, the cross-sectional shape according to the invention is provided at least in the angle zones A 1 , A 2 indicated here. The ball guide pocket inner geometry according to the invention can also be applied to separate zones, so that local guide paths are produced with the double contact guide function described above. FIG. 3 further illustrates the special geometry of the ring elements R 1 , R 2 according to the invention. As already described with respect to FIG. 1 , the ring elements R 1 , R 2 are constructed such that each of the bulging inner walls W 1 , W 2 bordering the ball guide pockets P 2 form a concave groove cross section for the ball 3 only indicated here with inner and outer ball contact zones Ki, Ka and the groove cross section is set deeper in a groove area Rm between these inner and outer ball contact zones Ki, Ka than the ball 3 contacting the ball contact zones Ki, Ka bulges toward this inner groove area. In the area between the inner and outer contact zones Ki, Ka, an intermediate space S is produced when the ball 3 contacts the bulging inner walls W 1 , W 2 . The maximum depth t of this intermediate space measured between the ball and groove area Rm is advantageously in the range of 1% to 7% of the ball diameter. FIG. 4A shows a state in which the ball bearing cage is displaced outward in the radial direction such that the ring elements R 1 , R 2 contact the ball 3 by their inner ball contact zones Ki. Incidentally, the statements for FIG. 1 also apply accordingly for this view. In the diametrically opposite ball guide pocket not shown here, the ring elements R 1 , R 2 are supported on the corresponding ball by the outer contact zones Ka. This contact state is shown in FIG. 4B . As can be seen from FIG. 4 b , the ring elements R 1 , R 2 can also contact the ball 3 by their outer contact zones Ka and thus guide the ball bearing cage formed by the two ring elements R 1 , R 2 such that this does not contact the bearing rings 1 , 2 . The ball bearing cage is thus reliably guided with roller bodies. FIGS. 5A and 5B show an embodiment of a ball bearing cage according to the invention in which the inner edges E 2 , E 3 , E 4 , E 5 of the ring elements R 1 , R 2 have a certain rounding. This rounding can be achieved by selecting the punching direction in the production of the ring elements R 1 , R 2 such that the punching burrs Z 2 , Z 3 , Z 4 , Z 5 form on the side of the ring elements R 1 , R 2 facing away from the ball 3 . Through the inward displacement of the ball contact zones Ki, Ka toward the ball equator, a ball bearing cage is created that offers improved contact and guide properties with respect to previous constructions. In the view according to FIG. 5A , the ball bearing cage contacts the ball 3 over its outer contact zones Ka. On the diametrically opposite side, the ball bearing cage contacts the ball 3 via the inner contact zones Ki as shown in FIG. 5B . LIST OF REFERENCE NUMBERS 1 Bearing inner ring 2 Bearing outer ring 3 Ball A 1 Angle zone A 2 Angle zone b Width (dimension) D Ball diameter E 2 Inner edge E 3 Inner edge E 4 Inner edge E 5 Inner edge Ka Outer ball contact zone Ki Inner ball contact zone P 2 Ball guide pocket Rm Groove base or bottom area R 1 Ring element R 2 Ring element S 2 Seating surface T Depth (dimension) W 1 Bulging inner wall W 2 Bulging inner wall Wa Straight outer wall section Wi Straight inner wall section W 3 Inner angle X Bearing axis Z Ball pocket center Z 2 Punching burr Z 3 Punching burr Z 4 Punching burr Z 5 Punching burr
A ball bearing cage having a first ring element and a second ring element is provided. The ring elements are each formed from sheet metal, and each include axial bulges separated by support surfaces. Ball guide pockets are formed between facing bulging inner walls by joining the support surfaces of the two ring elements. The ring elements are formed in such a way that the bulging inner walls that define the ball guide pockets define a channel cross-section which is concave in relation to a ball and which has an inner and an outer ball contact zone. The channel cross-section has such a depth in a groove base lying between said inner and outer ball contact zones that, when the ball comes into contact with the ball contact zones, an intermediate space remains between the ball and the groove base lying between the ball contact zones.
5
BACKGROUND OF THE INVENTION The present invention relates generally to a method and a device for detecting engine idling. More particularly, the invention relates to a method and device for detecting engine idling based on both the throttle valve angular position and the intake air flow rate. Generally, engine idling is detected by a throttle switch which is closed when the throttle valve is fully closed and/or the throttle valve open angle is less than a threshold value. Such a throttle switch requires relatively high accuracy for detection of the throttle angular position to produce a signal in response to the shifting of the throttle valve into the engine idle condition. Particularly, for an engine having a relatively large diameter induction system, such as, for example, the induction passage having a single barrel type throttle chamber, variation of air flow rate in response to varying of the throttle valve angular position is remarkable to make the detection of idling condition difficult. Therefore, for such engine, it is important to provide an accurate throttle switch. On the other hand, the engine idling condition may be detected by detecting the air flow rate lower than a threshold value defining the idle air flow rate. If the engine idling condition is detected based on the air flow rate, the throttle switch will not be required to have as high an accuracy as that otherwise required. SUMMARY OF THE INVENTION Therefore, it is an object of the invention to provide a method and device for detecting engine idling condition based on both the throttle valve angular position and the air flow rate. Another and specific object of the invention is to provide a method and device which detects an engine idling condition to produce a signal indicating that the engine is in an idle condition when the throttle switch is turned on and the air flow rate is less than a threshold value. To accomplish the above-mentioned and other objects of the invention, there is provided a method for detecting an engine idling condition, utilizing a throttle valve angular position with open angle less than a threshold angle value and an intake air flow rate, which is determined by an air flow meter provided in an air induction passage of an engine. The determined air flow rate is compared with a threshold value to distinguish if the determined rate is more than a idle air flow rate. A signal representative of an engine idling condition is produced when both conditions are satisfied, namely, when the throttle valve open angle is less than the threshold angle value and the intake air flow rate is less than the threshold value. Further to accomplish the objects, there is provided a device for detecting an engine idling condition, which includes a throttle angle switch producing a signal when the throttle valve open angle is less than the threshold angle value, an air flow meter for determining intake air flow rate, a means for producing a signal when the intake air flow rate determined by the air flow meter is less than a threshold value, and a means for producing a signal representative of the engine idling condition when both of the signals are present, which signals are respectively representative of the throttle valve open angle being less than the threshold angle value and the intake air flow rate is less than the threshold value. Therefore, according to the present invention, the throttle switch is not require to have high accuracy for detecting the engine idling condition, thus making manufacturing and assembling of the throttle switch easier. BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be more fully understood from the detailed description given herebelow and from the accompanying drawings of the preferred embodiment of the present invention, which, however, should not be taken as limitative to the invention, but for elucidation and explanation only. In the drawings: FIG. 1 is a schematic diagrammatical illustration of the preferred embodiment of an engine idling detecting device according to the present invention; FIG. 2 is an explanatory illustration showing a construction of a throttle switch applied to the engine idling detecting device of FIG. 1; FIG. 3 is a schematic diagram of an air flow meter circuit, which air flow meter circuit is applied to the engine idling detecting device of FIG. 1; and FIG. 4 is a graph showing variation of air flow meter output in relation to intake air flow rate. DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, particularly to FIG. 1, an engine idling detecting device includes an air flow meter 10 disposed in an air induction passage 12 of an internal combustion engine, downstream of an air cleaner 14. A throttle switch 16 is associated with a throttle valve 18 disposed within a throttle chamber 20 in the air induction passage 12. The throttle valve 18 is, in turn, connected to an accelerator pedal (not shown) via a linkage so that its angular position, called open angle, will vary in response to depression or release of the accelerator pedal. The throttle valve 18 controls the amount of intake air delivered to combustion chambers defined in an engine cylinder block 22 through an intake manifold 24. Fuel injectors 26 are provided in the intake manifold 24 to inject controlled amounts of fuel therein. The fuel injectors 26 are electrically connected to a control unit 28 such as a microcomputer which controls the ratio and timing of the open periods and closed periods thereof. As shown in FIG. 2, the throttle switch 16 comprises a rotatable member 30 rotatably disposed within a throttle switch housing 32. The rotatable member 30 is secured to an axle 34 which is connected with the pivot axle 36 of the throttle valve 18 via a linkage 38 so that it may rotate integrally with the pivot axle 36 in response to accelerator pedal movement. The rotatable member 30 is formed wih an irregularly-curved slot 40. A movable contact 42 of the throttle switch is placed in the curved slot 40 opposite a stationary contact 44. The slot 40 is adapted to allow the movable contact 42 to contact the stationary contact 44 at a position corresponding to a predetermined throttle valve angular position. The position in which the contacts 42 and 44 come into contact is selected to correspond to the fully-closed position of the throttle valve or to a throttle valve open angle less than a predetermined value, whichever more accurately indicates engine idling. Therefore, the contacts 42 and 44 close a circuit to produce a throttle angle signal S 1 whenever the throttle valve is fully closed or the throttle valve open angle is less than the predetermined value. The air flow meter 10 measures the intake air flow rate, and produces an air flow meter signal S 2 proportional to the intake air flow rate. The air flow meter 10 is provided with a flap 46 extending into the air induction passage 12. As the air flows through the induction passage, the flap 46 rotates to vary the resistance value of a potentiometer 48. As seen in FIG. 3, the potentiometer 48 comprises a movable contact 50 connected to a resistor 52 to produce a signal having a value proportional to the position of the movable contact 50. A terminal 51 is connected to the movable contact 50 via a lead 54 and a terminal 58 is connected to a terminal 56 via a resistor 60 and a lead 62. The terminal 56 is, in turn, connected to a terminal 64 via the resistor 52 and a lead 66. In this circuit construction, potential U across terminals 51 and 56 corresponds to the position of the movable contact 50 and varies with intake air flow rate as illustrated in FIG. 4. On the other hand, the potential U B across terminals 58 and 64 is a constant value determined by the resistance values of the resistors 52 and 60. The potentiometer 48 outputs the air flow meter signal S 2 , the value of which represents the potential U across the terminals 51 and 56 or U/U B which in turn correspond to the position of the movable contact 50. Both the throttle angle signal S 1 and the air flow meter signal S 2 are conducted to a detector circuit 68. The detector circuit 68 incorporates a discriminator 70 receiving the air flow meter signal S 2 . The discriminator 70 compares the air flow meter signal value with a reference value which represents a threshold value corresponding to the maximum idle air flow rate. The discriminator 70 produces a discriminator signal S 3 when the air flow meter signal value is less than the reference value. The detector circuit 68 further incorporates a gate circuit 72 such as an AND gate to produce a detector signal S 4 indicative of the engine idling when the signals S 1 and S 3 indicate respective conditions corresponding to idling. The detector signal S 4 may be fed to the control unit 28 as a control parameter for use in controlling engine operation.
Detection of engine idling is preformed by detecting the position of a throttle valve corresponding to idling and discriminating an intake air flow rate in a range of idle air flow rate. A signal indicative of engine idling is produced when both the throttle valve is in idling position and the air flow rate is less than the idle air flow rate.
5
CROSS REFERENCE Cross reference is made to the following applications, the disclosures of each of which are totally incorporated by reference herein: application Ser. No. 10/159,432, entitled “APPLICATION OF GLOSSMARKS FOR GRAPHICS ENHANCEMENT” to inventors Shen-ge Wang, Beilel Xu, and Chu-heng Liu; application Ser. No. 10/159,423, entitled “HALFTONE IMAGE GLOSS CONTROL FOR GLOSSMARKS” to inventors Shen-ge Wang, Beilei Xu, and Chu-heng Liu; application Ser. No. 10/186,065, entitled “VARIABLE GLOSSMARK”to inventors Beilei Xu, Shen-ge Wang, and Chu-heng Liu. The appropriate components and processes of the above co-pending applications may be selected for the invention of the present application in embodiments thereof. BACKGROUND The present invention in various embodiments relates generally the gloss inherent in the hardcopy of image data be it pictorial or text. More particularly, this invention relates to halftoned image data and the control of differential gloss when that halftone image data is printed into hardcopy. It is desirable to have a way to protect against copying or other fraudulent misrepresentation of a document. Most desirably in a manner that part of the content can be readily observed by a human reader but not by a copier scanner. It is particularly desirable that such a solution be available for such paper items as are commonly used publicly as icons of exchange. Two particular examples of such icons of exchange would be coupons and tickets, though there are many other paper items used as symbolic representations of exchange such as certificates, diplomas, passports, et cetera which are contemplated here as well. One approach is where an image is printed using clear toner or ink, creating a difference in reflected light and diffused light that can be discerned by a human reader by holding the paper at an angle, but cannot be detected by a copier scanner which is restricted to reading at right angles to the page. However, any such system needs to be inexpensive and resistant to tampering or manipulation. Coupons have long been utilized by manufacturers and retailers as an incentive to consumers. With the advent of the internet and the world-wide-web, the business world has responded by offering electronic versions of coupons. These coupons are downloaded and printed locally by the consumer. However, as these coupons have monetary value indicated thereon and are digital image data, they may be manipulated by the less scrupulous with an editing program running on a computer. It would be desirable to provide a print item less susceptible to such tampering. There has been a long felt need for a printer that can print a page that can be read but not copied. One method, described in U.S. Pat. Nos. 4,210,346 and 5,695,220, is to use a particular white toner and a particular white paper that are designed to have different diffused light characteristics at different angles. Of course, this system requires special, matched paper and toner. In U.S. Pat. No. 6,108,512 to Hanna, there is illustrated, for example, a system for producing non-copyable prints. In a xerographic printer, text is printed using clear toner. Thus, the only optical difference between toner and non-toner portions of the page is in the reflectivity. The plastic toner will reflect more light than the paper. A human reader can now read the image by holding the page at such an angle that the eye will intercept the reflected light from the toner, producing a contrast between the lighter appearing toner and the darker appearing paper. However, a copier scanner is always set up to avoid reflected light, by supplying light at an oblique angle and reading at a right angle. In this case, the diffused light is approximately equal for both toned and untoned surfaces, the scanner will detect no difference and the copier will not be able to copy the original. Another approach taken to provide a document for which copy control is provided includes digital watermarking. As an example, in U.S. Pat. No. 5,734,752 to Knox, there is illustrated a method for generating watermarks in a digitally reproducible document which are substantially invisible when viewed including the steps of: (1) producing a first stochastic screen pattern suitable for reproducing a gray image on a document; (2) deriving at least one stochastic screen description that is related to said first pattern; (3) producing a document containing the first stochastic screen; (4) producing a second document containing one or more of the stochastic screens in combination, whereby upon placing the first and second document in superposition relationship to allow viewing of both documents together, correlation between the first stochastic pattern on each document occurs everywhere within the documents where the first screen is used, and correlation does not occur where the area where the derived stochastic screens occur and the image placed therein using the derived stochastic screens becomes visible. For each of the above patents and citations, the disclosures therein are totally incorporated herein by reference in their entirety. The present invention relates to a method for protecting a printed item comprising printing a glossmark information indicia image upon the printed item. The glossmark information indicia image is realized by employing a methodology comprising selecting a first halftone having a first anisotropic structure orientation and selecting a second halftone having a second anisotropic structure orientation different from that of the first halftone. The first halftone is applied for at least some portion of the glossmark information indicia image, and the second halftone is applied for the remaining portion of the glossmark information indicia image. The present invention also relates to a print item comprising a substrate and an information indicia glossmark image printed on the substrate. The information indicia glossmark image further comprising an information indicia, a first halftone having a first anisotropic structure orientation and, a second halftone having a second anisotropic structure orientation different from the first halftone, where the first halftone is applied as to a portion of the information indicia glossmark image and the second halftone is applied as to the remainder of the information indicia glossmark image so as to depict the information indicia as a glossmark. The present invention further relates to a print item image comprising an information indicia, a background data image, a first halftone having a first anisotropic structure orientation and, a second halftone having a second anisotropic structure orientation different from the first halftone. The first halftone is selectively applied as to a portion of the background data image, and the second halftone is selectively applied as to a remainder of the background data image where the information indicia is used to select when to toggle between the first and second halftones such that the resulting print item image when printed will depict the information indicia as a glossmark. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows how the human eye can detect a large difference between the glossy portions of the page but a scanner detector cannot. FIG. 2 depicts a differential gloss found in simple line-screen halftones. FIG. 3 shows two 3×6 halftone patterns suitable in anisotropic structure to produce discernable gloss differential for practicing the present invention. FIG. 4 is a density sweep of the two halftone patterns of FIG. 3 . FIG. 5 depicts a patchwork alternating of the two halftone patterns of FIG. 3 so as to achieve a glossmark. FIG. 6 shows one embodiment for achieving the image directed alternation of the halftone patterns for glossmarks as depicted in FIG. 5 , utilizing the halftone patterns of FIG. 3 . FIG. 7 depicts a coupon embodiment of the present invention with information indicia as a glossmark. FIG. 8 shows a glossmark information indicia image before and after tampering. DESCRIPTION By proper utilization of the perceived differential gloss inherent between various anisotropic halftone dot structures, the desired manipulation of perceived gloss and the generation of glossmarks via that differential gloss may be achieved without the need for special paper or special toners or inks. By providing print items with information indicia glossmark images, those print item images may be protected from tampering. Such electronic print item images are exemplary for electronic distribution. FIG. 1 shows how the human eye 1 can read gloss upon the page and a scanner cannot. Three glossy areas 14 are shown. One ray of light 10 from the light source 2 hits the paper at a point where there is no gloss toner 14 , and the reflected light 13 is diffused so that there is only a small amount of light in all directions, including the direction toward the human eye 1 . Another ray of light 11 of equal intensity touches the paper at a point where there is gloss toner 14 . Here, there is a large amount of reflected light 12 in the indicated direction. If the human eye 1 is positioned as shown, a large difference between glossy and non-glossy toner areas is readily observable by the human eye 1 . However, the scanner 3 reads incident light at right angles to the paper. In this case, there is only a small amount of diffused light coming from both the glossy and non-glossy dots, and the scanner cannot detect a difference. This is one manner for creating a gloss image which cannot be scanned by conventional copiers and scanners. Heretofore, there has been little appreciation for the fact that the inherent reflective and diffusive characteristics of halftones may be manipulated to be directive of incident light as about an azimuth by use of a halftone structure which is anisotropic in nature. A mirror is equally reflective regardless of the azimuth of the light source relative to the plane of the mirror. Similarly, an ordinary blank paper is equally reflective and diffusive regardless of the azimuth of the light source. However, printed matter can and will often display differing reflective and diffusive characteristics depending upon the azimuth of origin for a light source relative to the structural orientation of the halftone. Such reflective characteristics when maximized are exhibited in a halftone with a structure which is anisotropic in nature. In other words, the indicatrix used to express the light scattered or reflected from a halftone dot will maximally vary depending upon the halftone dot's azimuth orientation to the light source when that halftone has an anisotropic structure. FIG. 2 provides an example of what is meant by anisotropic structure. In FIG. 2 , a simple line-screen halftone of anisotropic nature is presented in two orientations relative to impinging incident light 200 , a parallel orientation 210 , and a perpendicular orientation 220 . Both halftone dot orientations are selected to be similar in density so that the diffuse light and incident light at orthogonal angles to the paper are equal. In this way, the light which is available to scanner 3 or to the human eye from straight on is the same. However, the specular reflected light 12 is considerably greater for the anisotropic parallel orientation 210 . If as printed, a mass of the 210 parallel orientation halftones are butted directly adjacent to a mass of 220 perpendicular orientation halftones, there will be a difference in reflected light between them, which when viewed from an angle will be perceived as a shift in gloss differential or a glossmark. The perceptibility of this gloss differential will be maximized when the halftone anisotropic orientations are 90 degrees apart as shown here in FIG. 2 . FIG. 3 shows example halftone cells suitable for a skilled practitioner to employ in an embodiment employing the teachings of the present invention. They are but one useful example as will be evident to those skilled in the art. Each halftone cell is comprised as a three by six pixel array. The turn on/off sequence is numerically indicated. Note the diagonal orientation of the pixel numbering. The type-A sub-cell 310 and type-B sub-cell 320 both have a 45 degree orientation, one to the right and the other to the left. This orientation can be clearly seen in the density sweeps 410 and 420 of FIG. 4 . To maximize the perceptibility of the gloss differential, the orientations of sub-cells type-A and type-B are arranged 90 degrees apart one from the other. FIG. 5 depicts a glossmark image 500 achievable using halftone cells as described above. Screen-A 510 uses one halftone cell type and screen-B 520 uses the other. The circle 501 is provided as a visual aid across the image screens 500 , 510 and 520 . The desired glossmark here is for a sphere 502 to be perceived in the midst of image 500 . Screen-A 510 provides the field of right diagonal oriented anisotropic halftones and screen 520 provides the spherical area of left diagonal oriented anisotropic halftone cells. In this manner, a selection of the two screen types are patch-worked together to create the glossmark image 500 . An another approach for the assembly of a glossmark image is diagramed in FIG. 6 . Here, the primary image 600 is received as input data to the digital front-end (DFE) 610 as is normal. However, a desired glossmark image 620 is also received as input data to the DFE 610 as well. The processed image as sent to the image output terminal (IOT) 630 is a binary image by halftoning the primary image 600 data as is normal. However, the halftone type selection is driven by the intended glossmark image data 620 as input to multiplexer switch 640 . The intended glossmark image data 620 will serve to direct a portion of the primary image 600 to use a first anisotropic structured halftone while directing an alternative halftone to be used for the remainder of primary image 600 . As will be understood by those skilled in the art, the intended glossmark image data 620 may be flattened into simple zero and one pixel data representations if needed in the DFE 610 . This pattern of zero and ones are then used to toggle the multiplexer 640 to one halftone anisotropic structure orientation type or the other. Multiplexer 640 therefore toggles between either screen 1 type halftone 650 or screen 2 halftone type 660 , as dictated by the desired glossmark data 620 , to produce the composite result of raster input processed (RIP) image data as passed to the IOT 630 . In this way, a superimposition of a pattern 620 is imbedded into the primary image 600 which can only be perceived as gloss differential glossmark. In FIG. 7 , there is depicted an example of a coupon providing an embodiment of the present invention. An indicia of monetary value is to be superimposed as a glossmark 700 upon the coupon 710 in accord with the disclosure and description provided above as an information indicia glossmark image. The monetary indicia glossmark data 700 is depicted here as upon layer 720 for the ease of visualization. The data 700 is to be superimposed as per the technique of FIG. 6 onto the background gray tone area 730 of the coupon 710 . Such indicia when rendered as a glossmark, particularly when rendered at a high resolution, is not readily copied because copy machines are especially unequipped to detect and register gloss information. Furthermore, current image editing software for personal computer use is ill equipped to deal with glossmarks. This is important as far as electronically distributed coupons or tickets are concerned. Distribution of such printed items has been limited heretofore because of the potential for falsification by those deficient perhaps as to scruples or otherwise tempted. The problem arises from the relative ease with which personal computers enable the matching of fonts and editing of same, within any given digital image such as an electronic coupon or ticket comprises. This means that where indicia of coupon value (or the serial number for a ticket) is found these tools will allow the user to readily modify and thereby tamper with the monetary value (or serial number). The primary manner for which business have dealt with this problem has simply been to limit the value of coupons or tickets to relatively inconsequential amounts. In this way any redeemer is on-notice whenever there is a coupon for any significant monetary amount. Never-the-less, such tampering has been observed by various clearing houses which administer to the coupon trade. Glossmarking as to sensitive information to provide information indicia glossmark images allows for the expansion of electronic dissemination of such printed items because of its reticence to tampering while also providing ease of viewing and having no requirement for special paper or toner/inks. In short, glossmarking provides for greater security and is exemplary thereby for allowing the dissemination of larger value offerings without diluting any of the cost and convenience of dissemination benefits which made electronic coupons attractive to start with. It should be noted that the background gray tone area 730 need not be limited to the size shown in FIG. 7 . Indeed, in an alternative example it may comprise the entire background of the coupon 710 . Moreover, the area, where glossmarks are embedded, could be other than a constant-tone background. It could be with textures, hash-marks, different patterns, or even complicated images. Furthermore, the bar codes 740 though depicted as printed upon coupon 710 in FIG. 7 , may also be rendered upon the coupon 710 as glossmarks. In a similar manner, though not shown, serial numbers and tracking numbers could be rendered as information indicia glossmark images upon the coupon 710 . FIG. 8 depicts the indicia of monetary value glossmark image 700 in isolation for further examination. In addition to the “$0.35” indicia there are provided thereupon hash-marks 800 . The hash-marks 800 serve to provide visual indication of tampering. As currently available graphic manipulation software is unable to generate glossmark images, the only remaining approach for tampering with electronically distributed coupons containing glossmarks is with an block area “cut and paste” type of operation. FIG. 8 shows by example the result of just such an operation. Here, an attempt has been made to make the “$0.35” indicia read as “$5.30” simply by swapping the “5” and the “0” as depicted here in resulting glossmark image 810 . However, such an approach will erupt in image discontinuities visible as seams indicated here by the arrows 820 . As such, a clear visual indication of tampering is plainly made. In FIG. 8 , the hash-marks 800 are rendered as glossmarks. However, the hash-marks may also be rendered as normal background print as well or as part of background 730 . More importantly, and as will be apparent to those skilled in the art, there are any number of patterns which may be used instead of hash-marks. The hash-marks or any other repeating pattern used will ideally have a periodicity which is different from the effective periodicity of the numeric or other information indicia. Indeed, the pattern need not be repeating so long as it is varying enough such that it will be apparent when tampering has occurred. In closing, by applying sensitive print information as a glossmark information indicia image to various print items as would be used for public icons of exchange, the security and thereby the expanded availability for dissemination of such representations of exchange is meaningfully improved. This arrangement is exemplary for the accommodation of coupons and tickets. However, the invention as disclosed above, is not intended to be limited to coupons and tickets alone but also contemplates such items as certificates, passports, documents, citations, diplomas, currency and any other print items as may be comprised from printed items deemed desirable as icons for public exchange of value. The sensitive information or glossmark information indicia image may comprise time/date stamps, serial numbers, trademarks, indicia of monetary value, tracking codes, bar codes, logos, or any other indicia as would be desirably applied as a glossmark upon printed public icons of exchange, be they paper or other objects. Other embodiments and modifications of the present invention may occur to those skilled in the art subsequent to a review of the information presented herein; these embodiments and modifications, equivalents thereof, substantial equivalents thereof, or similar equivalents thereof are also included within the scope of this invention. All such variants are intended to be encompassed by the following claims:
The present invention relates to protecting printed items intended for public exchange having important informational indicia provided therein. The print items are protected from tampering by providing an informational indicia image as a glossmark. By selectively applying halftones with anisotropic structure characteristics which are significantly different in orientation while remaining identical in density to render information indicia, a glossmark image is produced of the information indicia. Such an information indicia glossmark image when provided in print item image helps protect that print item image from tampering.
7
BACKGROUND OF THE INVENTION The present invention relates to a technology effective in an application to an item print (such as, e.g., an address print etc) of printing items on a single label sheet on which a plurality of seals are laid out in lines. In recent years, a personal computer generally performs an address print such as a post card, a sealed letter and a label sheet etc. Incidentally, in a printing apparatus (a printer) of this type of personal computer, the label sheet has an area in which the printing is unable to effect (which will hereinafter be referred to as an unprintable area) in terms of a relationship between paper feed control and drive control of a printing head. This unprintable area is, to be specific, though different depending on specifications of the printers, a marginal area extending several mm ˜2 cm from a side edge of the label sheet, which is used by a paper feed mechanism (a roller) to draw in the sheet and discharge the sheet. Therefore, if many pieces of information such as, e.g., a post-code, an address, a name and a customer code etc are laid out in one single cell, the cell, if existing at a marginal area of the label sheet, comes to have an unclear print because of a limit by the area unprintable by the printing apparatus. Namely, when printing the information set in the cell extending to within the marginal area of the label sheet, a print position of the information might encroach on the unprintable area, with the result that there occurs such a phenomenon that the information can not be printed, or contents thereof (characters and images) are printed in discontinuity. Japanese Patent Application Laid-Open Nos. 2-277676, 5-244398 and 6-64233 disclose technologies of performing the print by reducing the whole data so that the data are well printed in an area and a label on the basis of a label dimension and information on the area printable by the printer. Those technologies disclosed therein are also capable of printing the data within the printable area (excluding the unprintable area) determined by the specification of the printer, however, the set-by-user information such as a set character font size etc is changed and does not reflect in a result of the print. Further, the whole data undergo the reducing process, and hence there arises a problem that the data, which should not (is not desired to) be reduced, might be reduced. It is a primary object of the present invention, which was devised to obviate the above problems, to provide a technology capable of printing without being influenced by an area unprintable by a printing apparatus while making set information reflected in the print, and in particular a technology effective in printing on a label sheet including a plurality of seals (cells). SUMMARY OF THE INVENTION To accomplish the above object, according to a first aspect of the present invention, a print controlling apparatus comprises a unit for obtaining an unprintable area on a print medium, a unit for judging whether or not data to be printed is printed in the unprintable area, and a unit for controlling, when judging that the data to be printed is printed in the unprintable area, the print of a fragment of data which extends to within the unprintable area. The unit for controlling the print of the fragment of data may compensate a print position of the fragment of data. The unit for controlling the print of the fragment of data may determine such a movement quantity that the fragment of data does not extend to within the unprintable area, and shift the print position of the fragment of data in accordance with the movement quantity. Further, the unit for controlling the print of the fragment of data may determine such a reduction rate that the fragment of data does not extend to within the unprintable area, and reduce the fragment of data in accordance with the reduction rate. According to the first aspect of the invention, the data to be printed may be data allocated to each item of a cell composed of a combination of a plurality of items, and the fragment of data may be data allocated to each item. Thus, only the fragment of data is set as an object for the control of the reduction and movement, and hence a well-laid-out print can be attained while making attributes (a size of a character font etc) of the original data reflected therein. In the print control, data that should not be reduced (the size should ne be changed) as in the case of a bar code may be excluded from the object for control. In this case, the unit for controlling the print of the fragment of data may determine such a movement quantity that each item of the cell does not extend to within the unprintable area, and shift a print position of the item in accordance with the movement quantity. Moreover, the unit for controlling the print of the fragment of data may determine such a reduction rate that each item of the cell does not extend to within the unprintable area, and reduce the item in accordance with the reduction rate. Further, in this case, the print controlling apparatus may further comprise a unit for storing a control flag showing whether or not a shift print is allowed per item, and the unit for controlling the print of the fragment of data may shift each item on the basis of the control flag. The print controlling apparatus may further comprise a unit for storing a control flag showing whether or not a reduction print is allowed per item, and the unit for controlling the print of the fragment of data may reduce each item on the basis of the control flag. On the other hand, the judging unit may judge, based on layout position information of cell items on the print medium, whether or not the data to be printed is printed in the unprintable area. The data allocated to the cell item may contain a state flag showing whether to extend to within the unprintable area or not, and the judging unit may judge based on the state flag whether or not the data to be printed is printed in the unprintable area. The unit for obtaining the unprintable area may obtain the unprintable area on the print medium corresponding to a printing apparatus for use. The print controlling apparatus may further comprise a unit for setting the unprintable area by a user, and the unit for obtaining the unprintable area may obtain the unprintable area set by the user. According to a second aspect of the present invention, a print controlling method comprises a step of obtaining an unprintable area on a print medium, a step of judging whether or not data to be printed is printed in the unprintable area, and a step of controlling, when judging that the data to be printed is printed in the unprintable area, the print of a fragment of data which extends to within the unprintable area. In this print controlling method, the step of controlling the print of the fragment of data may involve determining such a movement quantity that the fragment of data does not extend to within the unprintable area, and shifting the print position of the fragment of data in accordance with the movement quantity. Further, the step of controlling the print of the fragment of data may involve determining such a reduction rate that the fragment of data does not extend to within the unprintable area, and reducing the fragment of data in accordance with the reduction rate. Herein, the data to be printed may be data allocated to each item of a cell composed of a combination of a plurality of items, and the fragment of data may be data allocated to each item. In this case, the step of controlling the print of the fragment of data may involve determining such a movement quantity that each item of the cell does not extend to within the unprintable area, and shifting a print position of the item in accordance with the movement quantity. Moreover, the step of controlling the print of the fragment of data may involve determining such a reduction rate that each item of the cell does not extend to within the unprintable area, and reducing the item in accordance with the reduction rate. Furthermore, the step of controlling the print of the fragment of data may involve moving each item on the basis of the control flag showing whether or not a shift print is allowed per item. Still further, the step of controlling the print of the fragment of data may involve reducing each item on the basis of the control flag showing whether or not a reduction print is allowed per item. According to a third aspect of the present invention, there is provided a recording medium, readable by a computer, recorded with a program for making the computer execute a step of obtaining an unprintable area on a print medium, a step of judging whether or not data to be printed is printed in the unprintable area, and a step of controlling, when judging that the data to be printed is printed in the unprintable area, the print of a fragment of data which extends to within the unprintable area. The recording medium is a medium on which the program can be magnetically optically recorded, and embraces a magnetic tape, a magnetic disk and magneto-optic disk etc. Herein, the step of controlling the print of the fragment of data may involve determining such a movement quantity that the fragment of data does not extend to within the unprintable area, and shifting the print position of the fragment of data in accordance with the movement quantity, whereby the program can be recorded in an execution program format. Further, the step of controlling the print of the fragment of data may involve determining such a reduction rate that the fragment of data does not extend to within the unprintable area, and reducing the fragment of data in accordance with the reduction rate, whereby the program can be recorded in the execution program format. Furthermore, the data to be printed may be data allocated to each item of a cell composed of a combination of a plurality of items, and the fragment of data may be data allocated to each item. In this case, the step of controlling the print of the fragment of data may involve determining such a movement quantity that each item of the cell does not extend to within the unprintable area, and shifting a print position of the item in accordance with the movement quantity, whereby the program can be recorded in the execution program format. Moreover, the step of controlling the print of the fragment of data may involve determining such a reduction rate that each item of the cell does not extend to within the unprintable area, and reducing the item in accordance with the reduction rate, whereby the program can be recorded in the execution program format. Still further, the step of controlling the print of the fragment of data may involve moving each item on the basis of the control flag showing whether or not a shift print is allowed per item, whereby the program can be recorded in the execution program format. Yet further, the step of controlling the print of the fragment of data may involve reducing each item on the basis of the control flag showing whether or not a reduction print is allowed per item, whereby the program can be recorded in the execution program format. These together with other objects and advantages which will be subsequently apparent, reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout. BRIEF DESCRIPTION OF THE DRAWINGS Other objects and advantages of the present invention will become apparent during the following discussion in conjunction with the accompanying drawings, in which: FIG. 1 is a diagram showing a functional structure of an address printing system according to the present invention; FIG. 2 ( a ) is a diagram showing a state where an address items of a cell are overlapped with a marginal area; FIG. 2 ( b ) is a diagram showing a state where the address items of the cell are moved; FIG. 2 ( c ) is a diagram showing a state where the address items of the cell are printed in reduction; FIG. 3 is a diagram showing a layout state of a label sheet where the cells laid out in the marginal area are printed in reduction; FIG. 4 is a diagram showing a layout state of the label sheet where the cells laid out in the marginal area are moved; FIG. 5 is a flowchart showing an address print process in an embodiment 1; FIG. 6 is a flowchart showing a process of judging whether or not an address item exists off a print area in the embodiment 1; FIG. 7 is a flowchart showing a re-layout process in the address process in the embodiment 1; FIG. 8 is a flowchart showing the address print process in an embodiment 2; FIG. 9 is a flowchart showing the process of judging whether or not an address item exists off the print area in the embodiment 2; FIG. 10 is a diagram showing a cell layout in a label sheet; FIG. 11 is a diagram showing a layout of the address items in the cell; FIG. 12 is an explanatory diagram showing contents of layout information; FIG. 13 is an explanatory diagram ( 1 ) showing contents of direction data; FIG. 14 is an explanatory diagram ( 2 ) showing the contents of the direction data; FIG. 15 is an explanatory diagram ( 1 ) showing contents of cell address item layout information; FIG. 16 is an explanatory diagram ( 2 ) showing the contents of the cell address item layout information; FIG. 17 is an explanatory diagram ( 3 ) showing the contents of the cell address item layout information; FIG. 18 is an explanatory diagram ( 4 ) showing the contents of the cell address item layout information; and FIG. 19 is an explanatory diagram showing an input screen of a print area range. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiment 1 FIG. 1 is a diagram showing a functional structure of an address printing system by way of one embodiment of the present invention. Referring to FIG. 1, the numeral 101 designates an operation unit which is, to be specific, constructed of a keyboard or a mouse etc. A display unit 102 is constructed of a display device. A central processing unit (CPU) 103 has the following functions which are, to be specific, actualized by a program given from outside. A sub-storage unit 104 is composed of a hard disk and a memory (RAM). The sub-storage unit 105 includes a directory processing unit 105 . The directory processing unit 105 is constructed of an address item position compensation processing unit 106 and an address item layout unit 107 . The address item position compensation processing unit 106 is a functional unit for compensating a position of an address item disposed in each cell, and a specific process there will explained later on. The address item layout unit 107 is a functional unit for determining which items (an address and a name etc) are disposed in the cells and how. A printable area detecting unit 108 incorporates a function of detecting a printable area in a label sheet from information (corresponding to a marginal field), obtained by an OS (Operating System), on an unprintable area of a printing apparatus 121 and from layout information which will be mentioned later on. Herein, the function by which the OS thus acquires the information on the unprintable area of the printing apparatus connected to the principal units, is known in, e.g., MS-Windows by Microsoft Corp. An address printing processing unit 109 is defined as a functional unit for sending an indication and print data to the printing apparatus 121 . Note that an interface unit 110 for taking in address data from outside has a function of taking text data such as CSV file formatted data into the present address printing system. It is also to be noted that the principal units 103 - 110 , which are typical computer-assisted units like being personal computer-assisted, execute processing and control so that a program according to the present invention actualizes the respective functions through these principal units. The sub-storage unit 104 includes a layout information storage unit 111 , a cell item layout information storage unit 112 , and a directory data storage unit 113 . The layout information storage unit 111 is stored with the layout information as shown in FIG. 12 . The layout information consists of a type of label sheet, a name of maker, a size of label sheet, margin information, a cell interval, the number of columns, the number of rows, a cell size and a print area. These items of information are based on the information of the printing apparatus 121 which is set by the OS (Operating System), and the information on the marginal area 201 per printer is read from these items of information to the printable area detecting unit 108 . Herein, a relationship between the layout and the cell will be explained referring to FIGS. 10 and 11. A label sheet 1001 has a size of fixed form such as A 4 etc and is composed of a tack sheet of which a right side surface is coated with a silicon oil and a reverse side surface is an adhesive surface. Then, cells 206 are arranged corresponding to each other on this tack sheet. Further, as described above, a post-code item 201 , an address item 202 , a name item 203 and a customer bar code item 204 are printed on the cell 206 (see FIG. 11 ). Note that the cells can be arranged in five rows and three columns within a single label sheet in FIG. 10 . The cell item layout information storage unit 112 is stored with cell item layout information as shown in FIGS. 15-18. Referring to FIG. 15, xy coordinates (distance coordinates on the basis of a left upper point in the cell) of a start-of-print position and an end-of-print position and control flag 1701 can be set in each of the post-code item 201 , the address item 202 , the name item 203 and the customer bar code item 204 of the cell item layout information. The control flag 1701 contains a flag showing whether a display on the display unit 102 is given or not, its movement is allowed or not, and a reduction thereof is permitted or not, and so on. Referring to FIG. 16, a print width and a print height of each item are specified in stead of the end-of-print coordinates (x, y) of each item. Referring to FIG. 17, in addition to the control flag 1701 , a state flag 1901 is provided for each item. The state flag 1901 will be explained later on. Referring to FIG. 18, a print width and a print height of each item are specified instead of the end-of-print coordinates (x, y) of each item shown in FIG. 17 . The directory data storage unit 113 is stored with address data in formats as shown in FIGS. 13 to 16 . FIG. 13 shows a basic data storage format of the address data. As shown in FIG. 13, the address data consists of items such as a post-code, an address, a name, a date of birth and an implementation or non-implementation of bar code print. Further, the address item state flag 1901 is provided for each of these items, whereby an off-area state or an in-area state is set for each of the address items. This state flag 1901 will hereinafter be described. FIG. 14 shows another data storage format of the address data. The state flag 1901 may not be set herein. FIG. 2 shows a print state of the marginal area on the label sheet in this embodiment FIG. 2 ( a ) illustrates the print state of the marginal area when in a normal (conventional) address printing process. Referring to FIG. 2, the cell 206 is positioned downward on the right side on the label sheet 1001 , and the marginal area 205 indicates an unprintable area on the label sheet. Herein, a post-code 201 , an address 202 , a name 203 and a bar code 204 are printed as the address items 201 to 204 . As illustrated in FIG. 2, there is a state where the item of the bar code 204 extends to within the marginal area 205 in this print. FIG. 2 ( b ) shows a print state where print positions (cells) of the address items at the marginal area are shifted in this embodiment. As shown in FIG. 2 ( b ), as a result of moving all the address items (cells) upward, leftward and obliquely, the item of the bar code 204 is not overlapped with the marginal area 205 . FIG. 2 ( c ) shows a print state in which the print positions (cells) of the address items at the marginal area are shifted in reduction in this embodiment. As shown in FIG. 2 ( c ), the address items ((cells) are printed in reduction, and hence the item of the bar code 204 is not overlapped with the marginal area 205 . FIG. 3 illustrates a layout of the whole label sheet when the cells at the marginal area are printed in reduction. FIG. 4 shows a layout of the whole label sheet when the cells at the marginal area are moved inwardly of the sheet and thus printed thereon. FIG. 5 shows a processing flow in this embodiment. The processes in this embodiment will hereinafter be explained referring to FIG. 5 . To start with, the operation unit 101 inputs pieces of address data in sequence, and a directory is created (step 510 ). The directory may be created by reading CSV data from an outside address take-in unit 110 or data created by other applications ( 512 ). Next, the operation unit 101 and the address item layout unit 107 set a layout of the address print item in one single cell ( 513 ). This is executed specifically by a process of displaying a menu of the print items on the display unit 102 , and determining the print items by use of a mouse etc. Next, the operator indicates a start of the address print through the operation unit 101 ( 514 ). Upon the indication of starting the print, the CPU 103 determines a print area from the unprintable area information and the layout information of the printing apparatus 121 ( 515 ). Subsequently, the directory processing unit 105 judges based on a detected result of the print area detecting unit 108 whether or not the address items exist off the print area (which implies that address items exist in the marginal area 205 ) ( 516 ). This judgement step 516 will be explained in details with reference to FIG. 6 . Herein, however, it follows that the state flag (see FIGS. 13 and 15) of the relevant item is set to [off-area] if any one of the print items is overlapped with the marginal area 205 (as shown in FIG. 2 ( a )). In this embodiment, as in step 516 , it is judged from the state of layout of the respective items of the cells on the whole label sheet whether or not the address item is overlapped with the area off the print area (which is the marginal area 205 ). Next, the directory processing unit 105 extracts one set of address data from the director data storage unit 113 ( 517 ). Then, the directory processing unit 105 allocates the address data to the address print item of an unprinted cell on the label sheet ( 518 ). Subsequently, the directory processing unit 105 , referring to the state flag 1901 of the address data, judges whether or not [off-area] is set in any one of the address items (whether or not there is an item of which the print is overlapped with the marginal area) ( 519 ). In this case, if any one of the address items is set as [off-area], the processing proceeds to step 520 , wherein the address items are re-laid out ( 520 ). Further, all the state flags of the address items are set to [off-area], the relevant address data are transmitted to the address print processing unit 109 , and the processing returns to step 517 . Then, when all the address data are printed, the processing comes to an end ( 521 ). FIG. 6 is a flowchart showing details of the judgement step 516 in FIG. 5 . In this judging process, to begin with, the address data are extracted from the directory data storage unit 13 ( 601 ). Next, the address item layout unit 107 extracts the address print items (which are herein the post-code item 201 , the address item 202 , the name item 203 and the customer bar code item 204 ) from the address data ( 602 ). Subsequently, based on the address data extracted in step 603 , distances of the cells in which to print the address data from a left upper position on the label sheet, are added to the start- and end-of-print positions of the address items shown in FIGS. 15-18 ( 603 ). Next, with reference to the print area obtained in step 515 , it is judged based on the address item position (the xy coordinates) calculated in step 603 whether or not the print positions of those items intersect the marginal area 205 ( 604 ). Herein, if any one of the items intersects the marginal area 205 , this implies a case where the relevant address item can not be properly printed within the area on the label sheet, and therefore [off-area] is set in the state flag 1901 of the relevant address item. Whereas if the print position of the relevant address item does not intersect the marginal area 205 , the relevant address item is properly printed in the area on the label sheet, and hence the state flag 1901 of the relevant address item is set to [in-area] ( 606 ). When the setting of the state flag is thus completed with respect to all the address items and all pieces of address data, the judging process is completed ( 607 , 608 , 609 ). FIG. 7 is a flowchart showing details of the address item re-layout processing step 520 in FIG. 5 . Herein, the processes in this flowchart are executed if the state flag 1901 of any one of the address items is set to [off-area] in step 519 in FIG. 5 . At the first onset, there is obtained an area of the cell containing the address item of which the state flag 1901 is set to [off-area], is overlapped with the marginal area 205 ( 701 ). Next, there are obtained such a cell movement quantity and a cell reduction rate as to attain a state where the cell is not overlapped with the marginal area 205 ( 701 ). To be specific, when in the state shown in FIG. 2 ( a ), the whole cell is moved by −Δx, −Δy, whereby all the items, as shown in FIG. 2 ( b ), come to [in-area]. Further, when the whole cell shown in FIG. 2 ( a ) is reduced by approximately 80%, as illustrated in FIG. 2 ( c ), all the items come to [in-area]. Next, the address item compensation processing unit 106 reads one piece of address item data (e.g., the customer bar code item 204 ) of the relevant cell from the cell item layout information storage unit 112 (see FIG. 17 ). Herein, the control flag 1701 of this piece of address item data is read. If the control flag 1701 herein indicates [display] and [movable], the movement quantity (−Δx, −Δy) calculated in step 702 is added, thus setting a print re-layout position ( 705 , 707 ). Further, if the control flag 1701 indicates [display] and [reducible], the reduction rate (80%) calculated in step 702 is given as a multiplier to obtain a print re-layout position of the cell ( 705 , 709 ). Moreover, if the control flag 1701 indicates the [display] state, [movable] and [reducible], for example, at first, the calculated movement quantity (−Δx, −Δy) is added to each item of the cell, and it is judged whether or not a result of this addition is off the position of the relevant cell. As a result of this judgement, if not off the position of the relevant cell, this may be determined to be a print re-layout position. Whereas if off the position of the relevant cell, a reduction rate falling within the size of the relevant cell is obtained, and is given as a multiplier, thus setting a print re-layout position of the cell. Note that if the control flag 1701 indicates [non-display], the re-layout process is not executed at all, and the printing process is executed in the position as it is (corresponding to the state shown in FIG. 2 ( a ) Further, if the control flag 1701 indicates [unmovable], the movement quantity calculated in step 702 does not reflect in the re-layout. If the control flag 1701 indicates [irreducible], the reduction rate calculated in step 702 does not reflect in the re-layout either. Moreover, if the control flag indicates [movable] and [reducible], the moving process may be overlapped with the reducing process. Thus, the check of all the control flags 1701 of all the address items is completed, and the compensation position and the reduction rate are set (or non-setting) ( 711 - 713 ), the re-layout process (step 520 in FIG. 5) of the address items is completed. Note that in step 515 in FIG. 5 in accordance with the embodiment 1, the print area is determined from the unprintable area and the layout information of the printing apparatus 121 on the occasion of the determination of the print area but may also be set, by displaying an input screen of a print area range as shown in FIG. 19 on the display unit 102 and making the operator set the unprintable area (the marginal area 205 ) on the label sheet, based on a content of this setting and the layout information. Embodiment 2 FIG. 8 is a processing flowchart showing an embodiment 2 of the present invention. To start with, pieces of address data are inputted sequentially from the operation unit 101 , thereby creating a directory (step 801 ). This directory may also be created by reading the CSV data from the outside address take-in unit 110 and data created by other applications ( 802 ). Next, the operation unit 101 and the address item layout unit 107 set a layout of the address print item in one single cell ( 803 ). This is executed specifically by a process of displaying a menu of the print items on the display unit 102 , and determining the print items by use of a mouse etc. Next, the operator indicates a start of the address print through the operation unit 101 ( 804 ). Upon the indication of starting the print, the CPU 103 determines a print area from the unprintable area information and the layout information of the printing apparatus 121 ( 805 ). Subsequently, the directory processing unit 105 extracts one set of address data from the director data storage unit 113 ( 806 ). Then, the directory processing unit 105 allocates the address data to the address print item of an unprinted cell on the label sheet ( 807 ). Next, the directory processing unit 105 judges whether or not the address item exists off the print area on the label sheet 1001 ( 808 ). This judging step 808 will be described in details referring to FIG. 9 . In the embodiment 1, it is judged based on the layout state of the respective items of the cells on the, entire label sheet whether or not the address item is overlapped the area off the print area (which is the marginal area 205 ) (step 516 in FIG. 5 ). By contrast, according to the embodiment 2, the above judgement is made when cells are developed on the label sheet (step 807 ). Next, referring to the state flag 1901 of, the directory data set in the judging step 808 , it is judged whether or not [off-area] is set in any one of the address items (whether or not there is an item of which the print is overlapped with the marginal area) ( 809 ). In this case, if any one of the address items is set as [off-area], the processing proceeds to step 810 , wherein the address items are re-laid out ( 810 ). Further, all the state flags of the address items are set to [in-area], the relevant address data are transmitted to the address print processing unit 109 , and the processing returns to step 806 . Then, when all the address data are printed, the processing comes to an end ( 811 ). FIG. 9 is a flowchart showing details of the judgement step 808 in FIG. 8 . To begin with, the address item layout unit 107 extracts the address items from the address data ( 901 ). Subsequently, based on the address data extracted in step 107 , distances of the cells in which to print the address data from a left upper position on the label sheet, are added to the start- and end-of-print positions of the address items shown in FIGS. 15-18 ( 902 ). Next, with reference to the layout information (FIG. 12) in the sub-storage unit 104 , it is judged based on the address item position (the xy coordinates) calculated in step 603 whether or not the print positions of those items intersect the marginal area 205 ( 903 ). Herein, if any one of the items intersects the marginal area 205 , this implies a case where the relevant address item can not be properly printed within the area on the label sheet, and therefore [off-area] is set in the state flag 1901 of the relevant address item. Whereas if the print position of the relevant address item does not intersect the marginal area 205 , the relevant address item is properly printed in the area on the label sheet, and hence the state flag 1901 of the relevant address item is set to [in-area] ( 905 ). When the setting of the state flag is thus completed with respect to all the address items, the judging process is completed ( 906 , 907 ). Note that in step 805 in FIG. 8 in accordance with the embodiment 2, the print area is determined from the unprintable area and the layout information of the printing apparatus 121 on the occasion of the determination of the print area but may also be set, by displaying the input screen of the print area range as shown in FIG. 19 on the display unit 102 and making the operator set the unprintable area (the marginal area 205 ) on the label sheet, based on a content of this setting and the layout information. The many features and advantages of the invention are apparent from the detailed specification and, thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
An unprintable area on a label sheet is at first obtained so that a print is not overlapped with the unprintable area on the sheet when laying out print items in cells of a tack sheet etc. It is judged whether or not address data is printed in the unprintable area, and, if a print position of the address data is overlapped with the unprintable area, a print of a fragment of data extending to within the unprintable area is so controlled as to be reduced and moved. Only the fragment of data is set as an object for the control of the reduction, and movement, and hence a well-laid-out print can be attained while making attributes (a size of a character font etc) of the original data reflected therein. In the print control, data that should not be reduced (the size should ne be changed) as in the case of a bar code may be excluded from the object for control.
6
BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates to a cable and pulley arrangement that provides for minimal slippage of the cable about the pulley. It is particularly well suited for applications requiring accurate and repeatable movements of devices attached to such pulleys, such as motorized and automated Pan/Tilt/Zoom Cameras with predefined fields of view. 2. Discussion of Related Art Pulley and Cable arrangements are often used to control the movement of a device connected to one pulley via the controlled movement of another pulley. For example, a security camera's field of view can be adjusted in the horizontal or vertical direction by controlling one or more motors that are connected by pulley and cable to a movable platform upon which the camera is attached. Another example is the manual rotation of a wheel to effect the rotation of another device, such as the rudder of a boat. To maintain a correspondence between the rotation of the driving pulley and the driven pulley, the cable which is routed about the pulleys is maintained under tension, and the resultant friction forces a relatively fixed relation between each pulley and the cable. Often, due to the nature of the construction of the cable, for example as a braided filament of finer strands, the frictional forces are not equivalent in both directions of rotation of the pulleys. This can result in a gradual creeping of the cable in the direction of lesser frictional force, such that the correspondence between the driving and driven pulleys is no longer maintained. To reduce the slippage in half, traditional devices often comprise a cable that is fixedly attached to one pulley, and frictionally held to the other. Fixedly attaching the cable to both pulleys is not effective, for it introduces hysteresis, or backlash, as the cables stretch over time and the driving pulley must initially take up the slack before a movement occurs on the driven pulley. Cable stretching also allows for overshoot, as the inertia of the driven object causes it to continue to rotate when the driving motor stops. To compensate for cable stretch, the driving and driven pulleys are typically maintained under high tension, using for example, spring mounted pulleys. Alternatively, to assure a proper and repeatable correspondence between the rotation of the driving pulley and the driven pulley, a modified pulley and cable arrangement may comprise a toothed wheel and a chain. When the driving pulley is rotated, the chain holds an absolute position relative to the wheel because of the interlocking of the chain and the teeth of the wheel. Such a chain driven apparatus, however, typically exhibits the aforementioned hysteresis, or backlash. To reduce the hysteresis caused by the chain linkage, hybrid devices typically comprise a chain and toothed gear on the driving pulley, and a fixedly attached cable on the driven pulley. To overcome the hysteresis of a chain, or the slippage of a filament, or both, the static tension on the chain or cable must be high. To accommodate the forces produced by the high tension between pulleys, the supporting structures, holding the pulleys apart and maintaining the tension, must be reinforced. This reinforcement adds additional weight and cost to the apparatus, a weight and cost which could be reduced by minimizing the need for high tension between the pulleys. SUMMARY OF THE INVENTION It is an object of this invention to provide a means for maintaining a correspondence between the orientation of a drive pulley and a driven pulley. It is a further object of this invention to minimize the slippage of a pulley and cable arrangement. It is a further object of this invention to minimize the hysteresis, or backlash, of a pulley and cable arrangement. It is a further object of this invention to minimize the hysteresis and slippage of a pulley and cable arrangement without introducing significant additional costs. These objectives have been realized by fixedly attaching a locator ball on the cable, and a corresponding locator hole on the pulley. Through the interaction of the ball and the hole, a significant frictional advantage can be achieved, without requiring excessively high tension between the pulleys. Further advantages can be achieved by combining this locator ball approach with a fixedly attached cable approach, as will be discussed below. BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1A and 1B shows a cable drive for a Pan/Tilt/Zoom camera. FIGS. 2A-2C shows a cable and pulley apparatus in accordance with this invention. FIGS. 3A and 3B shows a cable drive for a Pan/Tilt/Zoom camera in accordance with this invention. FIGS. 4A and 4B shows alternative cable locator pin arrangements in accordance with this invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS FIGS. 1A and 1B shows a cable drive for a Pan/Tilt/Zoom camera. A motor, not shown, effects the rotation of the driving pulley 110. If cable 160 is properly tensioned, a rotation of the driving pulley 110 causes a movement of the cable 160. The driven pulley 130 is rotated by the action of the movement of the cable 160. The idler wheels 120 allow for a change of direction of the cable, thereby allowing a rotation of the driving pulley about a vertical axis to be converted to a rotation of the driven pulley about a horizontal axis. As shown, this cable and pulley arrangement produces a tilt of a camera 101, which is axially attached to the driven pulley 130, in direct relationship to the rotation of the driving pulley. Traditionally, the camera 101 is adjusted while the adjuster is viewing the scene within the camera's field of view. The motor which drives the driven pulley is energized to rotate in one direction or the other until the desired scene comes into view. In such a system, a precise correspondence between the rotation of the motor and the tilt of the camera is not required. As long as the slippage and the backlash of the cable is not excessive, the user can effect the relative motion of the camera to eventually produce the desired view, without regard to the absolute motion of the motor. That is, for example, assuming nominal slippage, the motor may turn 31 degrees clockwise to achieve a 30 degree change in camera angle, and only 28 degrees counterclockwise to achieve an opposite 30 degree change in camera angle. This difference in absolute measures would typically be caused by hysteresis, or backlash, as well as a difference in friction between the cable and the pulley in each direction. Such a difference, however, would be virtually undiscernible to an operator who is adjusting the camera by viewing the scene. Thus, in a traditional, manually controlled, system, the tension on the cable 160 would be merely the tension required to avoid a discernible hysteresis or slippage. Shown in FIGS. 1A and 1B is a tension control mechanism 150. Such a tension control mechanism, common in the art, comprises a torsion spring, not shown. In FIGS. 1A and 1B, cable 160 is not a continuous loop; one end of cable 160 is fixedly attached to pulley 130, and the other end is attached to the tension control mechanism 150, which is fixedly attached to pulley 130. Tension control mechanism 150 applies tension to one end of the cable, which tension is equal and oppositely applied at the fixedly attached end. As discussed above, the amount of tension provided is typically the amount required to avoid noticeable slippage or backlash. Alternatively, as is known in the art, the idler pulleys 120 could be spring loaded so as to exert a force on the cable 160 in a direction away from the driving and driven pulleys. Increasingly, camera angle adjustment means such as shown in FIGS. 1A and 1B are automated via computer control. Camera control systems allow for the setting of predefined camera views. The user adjusts the camera, via manual control, to a desired view. The user then instructs the camera control system to remember this view. At a later point in time, after subsequent changes to the camera view, the user instructs the camera control system to reposition the camera to the aforementioned remembered view. As compared to the human's repositioning of the camera based upon the view presented by the camera as it is moved, the camera control system effects this repositioning via precise commands to the motor which drives the driving pulley. As is evident in such a system, the ability to reposition the camera via commands to the motor necessarily implies an absolute correspondence between a rotation of the driving pulley and a rotation of the driven pulley. As is known in the art, the force which can be applied to rotate the driven pulley is limited by the frictional forces opposing the motion of the cable relative to the pulley. The traditional means of maintaining an absolute correspondence between a driving and a driven pulley is to significantly increase the tension in the cable between these pulleys, thereby increasing the frictional forces to oppose the relative motion, or slippage, of the pulley and the cable. Shown in FIGS. 2A-2C is a pulley and cable arrangement which does not require a significant tension to maintain a relatively fixed correspondence between the cable and the pulley. The pulley 210 has a locator hole 280 for receiving a locator ball 270 which is fixedly attached to the cable 260. Assuming a minimal static tension holding cable 260 against pulley 210, a movement of cable 260, via a pulling force on the cable at 260a or 260b will result in a movement of the locator ball 270, which is fixedly attached to the cable, and a corresponding movement of pulley 210, due to the forces applied to the edge of the hole 280 by the surface of the ball 270. As detailed in FIG. 2B, the pulling force FP exerts a force FH against the edge of the hole 280, and a lifting force FL perpendicular to FH. These forces are dependent upon the relative size of the ball compare to the cable. Assuming a ball having at least twice the diameter of the cable, a significant portion of the pulling force is applied to move pulley 210. That is, by employing the locator ball, in accordance with this invention, the pulling force itself assures a corresponding movement of the pulley. The tension force required is merely that which is required to overcome the lifting force FL. As compared to a fixed attachment of the cable to the pulley, the use of a locator ball provides the same amount of rotational correspondence, provided that the ball is not lifted from the hole. However, it provides a significant manufacturing, and serviceability advantage to a fixed attachment by merely requiring the cable to be laid about the pulley such that the ball and hole line up, rather than requiring a means of fixedly attaching the cable. As would be evident to one skilled in the art, the pulley 210 could contain multiple locator holes 280, to ease manufacturing or installation setup, by allowing the locator ball 270 to be placed in whatever hole was most convenient. Thereafter, the correspondence of the motion of the cable and pulley would be maintained, relative to that initial placement. As would also be evident to one skilled in the art, the device as shown in FIGS. 2A-2C would maintain a correspondence between the movement of the cable and the movement of the pulley only while the locator ball is located on the perimeter of the pulley; i.e. through approximately 180 degrees of motion of the pulley. As would be evident to one skilled in the art, however, the amount of rotational movement can be extended by allowing for multiple turns of the cable about the pulley, as shown in FIG. 2C. Shown in FIG. 2C is a pulley 215 having a screw-like channel 290 which extends at least one full revolution on either side of the locator hole 280. If the cable 260 is wrapped around the pulley 215 for two full revolutions, with the locator ball 270 at the center of these two revolutions, the extent of rotation of the pulley would be +/-270 degrees, for a total of 540 degrees of rotation. If additional revolutions are provided by channel 290 and the cable 260 is corresponding additionally wrapped around the pulley 215, the extent of rotation can be extended. Alternatively, if an unlimited span of rotation is required, a continuous loop of cable with multiple locator balls, appropriately spaced, could provide for limitless rotation. In this way, it is seen that the use of locator balls and holes provides an operational advantage over the fixed attachment of the cable to the pulley, which inherently has a fixed limit of rotation. The use of multiple locator balls and holes, does however, require a precise placement of the balls and holes relative to each other, to prevent slippage as each ball engages and disengages its corresponding hole. As discussed above, a single ball system, albeit limited in freedom of rotation, requires no such precision, because, once initially located in the hole, all subsequent rotations will be relative to that initial location, and no slippage can occur as long as the ball remains within the hole. Although the locator item on the cable has been discussed thus far as being a ball, it is evident that alternative shapes could be employed. For example, for increased purchase, a cylindrical locator 470 could be fixedly attached to the cable 260, with a matching cylindrical hole 480 in the pulley, as shown in FIG. 4A. Similarly, a pin 471 could be inserted into the cable 260, traversing its diameter, and notches 481 placed in the outer rim of the pulley, suitably sized to receive the ends of the pin, as shown in FIG. 4B. These and other like means for securing a protuberance located on a cable to a pulley would be evident to one skilled in the art, and are within the scope of this invention. FIGS. 3A and 3B shows a Pan/Tilt/Zoom camera arrangement, similar to FIGS. 1A-1C, but with a locator ball and hole in accordance with this invention. Items in FIGS. 3A-3B which correspond to those in FIGS. 1A and 1B have the same reference numerals and function as described above. Shown is a locator ball 365 fixedly attached to the cable 160. The pulley 310 contains one or more holes for receiving the locator ball 365. Typically, because the tilt angle need only be varied between 0 degrees (horizontal) and 90 degrees (vertical), the locator ball is positioned such that, at midpoint of its traversal on pulley 310, the camera is oriented at 45 degrees. Pulley 130, having the cable fixedly attached, directly and via the torsion spring, is situated such that the fixed attachment points are midway about their traversal on pulley 130 when the camera is oriented at 45 degrees. Once the locator ball is situated on pulley 310, and the cable is tensioned, subsequent movements of pulley 310 will induce a corresponding movement in pulley 130, with no slippage; and, assuming that the locator hole is sized with sufficient precision relative to the size of the locator ball, with no backlash, or hysteresis. As would be evident to one skilled in the art, the cable may be, equivalently, fixedly attached to pulley 310 and the locator hole formed in pulley 130. As previously mentioned, the torsion spring maintains sufficient tension on the cable to minimize the backlash caused by cable slack. To minimize the slack, the tension must be greater than the force required to move the load on the pulley 130. Typically, the load is balanced about the axis of rotation, and thus, the required tension force can be minimized. Alternatively, the idler wheels 120 could be tensioned to provide the cable tension. It is noted that, in accordance with this invention, high tension forces are not required to maintain the correspondence between the movements of the pulley and the cable, because the placement of the locator ball into the locator hole on the pulley provides the necessary fixed correspondence. The foregoing merely illustrates the principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the invention and are thus within its spirit and scope.
A cable drive apparatus is presented which has minimal cable slippage and backlash. Such a cable drive is particularly well suited for systems requiring accurate positioning and repositioning capabilities, such as motorized camera orientation systems. To achieve minimal slippage on a cable driven pulley, one or more positioning balls are located at fixed locations on the cable, and corresponding positioning holes are located on either pulley. Tensioning means are also provided to remove slack, to minimize the backlash which may result from the stretching of the cable over time. A two pulley system is presented wherein the cable is fixedly attached to one pulley, travels over the other pulley which has the slippage constraining positioning holes, and then to tensioning means which also fixedly attached to the first pulley.
8
CROSS-REFERENCES TO RELATED APPLICATIONS This application is a continuation-in-part of my co-pending U.S. patent application Ser. No. 767,114, filed Aug. 19, 1985, now U.S. Pat. No. 4,677,949. BACKGROUND OF THE INVENTION Examples of the prior art of scroll-type fluid displacement apparatus are disclosed in the below listed patents: ______________________________________ Patentee______________________________________U.S. Pat. No. 801,182 Creux3,817,664 Bennett et al3,884,599 Young et al3,994,635 McCullough4,129,405 McCullough4,192,152 Armstrong et al4,300,875 Fischer et al4,343,599 Kousokabe4,484,869 Nakayama et al4,490,099 Terrauchi et al4,497,615 Griffith4,505,651 Terrauchi et al4,515,539 Morishita4,550,480 Tanikawa et al4,553,913 Morishita et alFrench Patent No. 836,142 Lasnier______________________________________ The prior art discloses scroll apparatus employed to pump and compress fluids, and also as motors or engines driven by fluids. However, the prior art makes no suggestion of a scroll apparatus as an internal combustion engine. A scroll apparatus may be considered as spiral wraps interfitting in a tangential relation to define a pocket between the wraps and relatively orbital to move the pocket and enlarge or reduce its size according to the direction of orbital movement. SUMMARY OF THE INVENTION Other objects of the present invention will become apparent upon reading the following specification and referring to the accompanying drawings, which form a material part of this disclosure. The invention accordingly consists in the features of construction, combinations of elements and arrangements of parts, which will be exemplified in the construction hereinafter described, and of which the scope will be indicated by the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a transverse sectional view showing a scroll type apparatus constructed in accordance with teachings of the present invention. FIG. 2 is a sectional view taken generally along the line 2--2 of FIG. 1. FIG. 3 is a sectional view taken generally along the line 3--3 of FIG. 1. FIG. 3A is a sectional view taken generally along the line 3A--3A of FIG. 2 FIG. 4 is an end view illustrating an early stage in manufacture of a scroll element according to the instant invention. FIG. 5 is a plan view showing the manufacture according to FIG. 4. FIG. 6 is an end view showing a later stage in the instant method. FIG. 7 is a sectional view taken generally along the line 7--7 of FIG. 6. FIG. 8 is a sectional view similar to FIG. 7 but showing a slightly modified embodiment of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now more particularly to the drawings, and specifically to FIGS. 1 and 2, an internal combustion engine is there generally designated 10 and may include a casing 11 suitably fixed, as by brackets 12 to a support 13. The casing 11 may include a pair of complementary casing sections 15 and 16 which may each be generally cylindrical in facing, spaced relation with each other to define a generally closed cylinder enclosing a generally cylindrical interior space 17. More specifically, the casing section 15 may include a generally flat, circular side wall 18 having an inwardly extending peripheral wall 19. Extending along the inner edge of the peripheral wall 19 is a flange 20, radially outstanding beyond the peripheral wall, and provided on its outer edge with an in-turned securement lip 21. At one location about the periphery of the side wall 15, the peripheral wall 19 is provided with an air inlet conduit 22 communicating between the exterior and interior of the casing 11. The side wall 23 of casing 16 is essentially similar to the casing side wall 18 being generally flat and of circular configuration, having a peripheral, inwardly extending wall 24 provided on its inner edge with a circumferentially radially outstanding flange 25. The radially outer edge of the flange 25 is provided with a circumferentially extending, inturned securement lip 26 in edge to edge relation with the securement lip 21 of the casing section 15. The casing lips or securement edges 21 and 26 may be suitably secured, as by a circular array of bolts or fasteners 27, and suitably sealed, as by desired gasket means. At one location about the peripheral wall 24 of the casing section 16 there may be provided a fluid outlet or exhaust conduit 28 communicating between the interior space 17 of the casing 11 and the exterior thereof. The generally annular flanges 20 and 25 extend in facing, spaced relation with each other and combine with their inturned lips 21 and 26 to define an annular channel or groove 30 extending generally circumferentially about the cylindrically shaped casing 11 and opening radially into the interior hollow 17 of the casing. The annular channel or groove 30 opens radially outwardly, as by interruptions 44 and 47 in the securement edges or flanges 21 and 26, for purposes appearing presently. A rotor is generally designated 31 and located interiorly of the casing 11. The rotor may include a generally flat, approximately circular plate 32 having its circumferential margin 33 extending into the channel 30 entirely thereabout. That is, the marginal edge portion 33 of the rotor plate or wall 32 extends into the circumferential casing groove or channel 30 entirely thereabout, terminating short of the channel lips 21 and 26 to permit of orbital movement of the rotor by rotary translation in the manner of scroll type apparatus. A description of scroll apparatus construction may be obtained from prior art patents, such as U.S. Pat. No. 4,490,099 to Terrauchi et al and 4,343,599 to Kousokabe. The generally circular plate or rotor 32 may be provided with a pair of angularly spaced, generally radial extensions, as at 29 and 38, respectively extending through openings 44 and 47 formed in the meeting edge flanges 21 and 26. As noted, the rotor plate or wall 32 moves in a circular, translational orbit extending into the groove 30; and, suitable sealing means, such as O-rings or gaskets 34 and 35 may be interposed between the rotor plate 32 and channel walls 20 and 25, respectively. Thus, the rotor plate 32 may subdivide the interior 17 of the casing 11 into a pair of chambers 36 and 37 in side-by-side relation on opposite sides of the rotor. The chamber 36 may be considered as the inlet or compression chamber, while the chamber 37 may be considered as the outlet or expansion chamber. A pair of crank shafts 39 and 39a are suitably journalled, in generally parallel relation, in a fixed support 48, each shaft including an eccentric or crank, as at 40 and 40a, respectively. The eccentrics 40 and 40a are journalled in and extend rotatably through respective rotor extensions 29 and 38. Transmission means, such as toothed wheels 64 and 64a may be keyed to respective shafts 39 and 39a, and suitably geared together as by a chain or belt 66. Thus, rotation of one of the shafts 39, 39a will rotate the other in timed relation to effect the circular translatory orbital movement of rotor 31, as in scroll apparatus. Other suitable means may be provided for constraining the rotor to its orbital motion. In scroll-type fluid displacement apparatus there are included a pair of generally identical spiral walls or wraps interfitting with each other and combining with each other and end plates or closures to define closed pockets which move spirally and radially upon relative orbital movement between the spiral wraps. In particular, a pair of diametrically opposed, closed pockets move radially and spirally inwardly and reduce in size to effect compression of fluid in the pockets, see for example U.S. Pat. No. 4,490,099, FIGS. 1a through 1d. Upon reversed circular translatory orbitting, the diametrically opposed pockets move radially and spirally outwardly and increase in size for expansion of the fluid contents. This reversal of compression to expansion may be effected also by providing spiral wraps of opposite angular direction, while retaining orbital movement of the same direction as for compression. Further, it will be understood that, as from U.S. Pat. No. 4,490,099, the opposed, closed pockets of reducing size are closed or out of communication with each other, until the fluid arrives in a substantially compressed condition, that of FIG. 1d, when the opposed pockets open to or communicate with each other as a single central closed pocket. Conversely, upon expansion the central closed pocket expands into a pair of diametrically opposed, closed expanding pockets moving radially and spirally outwardly. The pair of opposed pockets are closed and out of communication with the central opening or passageway, while the central pocket opens or communicates through the central passageway, as will appear more fully hereinafter. Fixed on the internal surface of casing wall or end plate 18 is a spiral compression wrap or wall 45 of somewhat more than two convolutions. An identical spiral wrap or wall 46 is fixed to and outstands from the rotor wall or end plate 32 into the compression chamber 36, being angularly off-set approximately 180° from the wrap 45 and radially off-set by the eccentric distrance of cranks 40 and 40a. This may be seen in FIG. 2 where it will be appreciated that rotation of the crank shafts 39 and 39a in the counterclockwise direction of arrow 47 to orbit the movable spiral wrap 46 counterclockwise, will result in the drawing of fluid inwardly through inlet passageway 22 into the radially outer regions of chamber 36 and thence by size reduction of the opposed pockets centrally to a central pocket. A central aperture or passageway 41 is formed in the rotor wall or plate 32 through which compressed fluid in the central pocket may exit into the central region of the expansion chamber 37. Thus, it will be appreciated that the fixed and orbital wraps 45 and 46 may be considered compression wraps, and combine with the casing wall 18 and rotor wall 32 to define a compressor. Extending into chamber 37 from casing end plate or wall 23, and fixed thereto, is a spiral wall wrap 49, see FIG. 3. A similarly oriented spiral wall or wrap 50 is provided on and projects from the rotor end plate or wall 32 into the chamber 37. As best seen in FIGS. 2 and 3, the spiral wraps 45 and 46 of chamber 36 are oriented in one angular direction, and the spiral wraps 49 and 50 in the chamber 37 are oriented in the opposite angular direction. Thus, upon rotation of the rotor 31 to effect orbital movement of the movable spiral wraps 46 and 50 in the same angular direction, the cooperating pairs of spiral wraps will cooperate oppositely. As noted hereinbefore, the spiral wraps or walls 45 and 46 will compress fluid radially inwardly. Conversely, the spiral wraps 49 and 50 will expand fluid radially outwardly. Thus, fluid entering chamber 37 through port or passageway 41 will expand and move radially outwardly in chamber 37 for discharge through outlet 28. The spiral wraps 49 and 50 may therefore be aptly termed the fixed and moveable expansion spiral wraps, respectively. Desireably the fluid or air entering in the conduit 22 may be provided with a lubricant, such as by oil dispenser or oiler 51 to lubricate and minimize wear on the contacting surfaces of the spiral wraps and end plates. Also, fuel may be introduced into the air entering conduit 22, say together with the oil, if desired. Of course, fuel may be introduced at a different location, for example, fuel may be introduced by injection into the compressed air in a central pocket, if desired. If desired, suitable sealing means may be provided, along the edges of the spiral wraps, to further seal the pockets described hereinbefore. In the expansion chamber 37, at diametrically opposed locations adjacent to but radially outward of the central region, there may be provided a pair of spark plugs, as at 53 and 53a in the casing wall 23. Thus, the spark plugs 53 and 53a introduce ignition into the pair of closed, diametrically opposed expanding pockets, for combustion and expansion to drive the apparatus. That is, the products of combustion expand in the opposed pockets of the expander to drive the rotor 31, and thereby drive shafts 39 and 39a the products of combustion exhausting through the outlet conduit 28. An accessory mounting bracket 57 may be provided on a casing wall 18, mounting a transmission gear or wheel 55 driven as by a belt 54 from one of the shafts 39, 39a to rotate an accessory shaft 56. The bracket 57 may mount a fuel pump 58 and a distributor 59, which are respectively driven, as by driving means 60 and 61 from the shaft 56. The fuel pump 58 may be connected by conduits 62, say to the fuel feed device 51, or other suitable fuel feed or injector. The distributor 59 may be connected, as by conductors 63 to deliver the spark to plugs 53 and 53a, in properly timed relation to effect combustion of charges in expanding, closed diametrically opposed pockets. This maintains operation of the engine 10 and, produces useful work at the shafts 39 and 39a. Suitably mounted, as by fixing to the support 48, may be a starter motor 65, which may be in meshing, driving relation with chain or belt 56 for initiating operation of the engine. In FIGS. 4 and 5 are illustrated an initial stage in manufacture of a scroll element, wherein a plurality of sheets, strips or laminations 70, 71, 72, 73, 74 and 75 are arranged in longitudinally extending relation with each other and are arranged in superposed or overlying, facing engagement. The lowermost, elongate sheet, strip or lamination 70 may be relatively wide, as between opposite side edges 76 and 77, while the remaining elongate strips or laminations 71-75 are of equal, relatively narrow width and superposed one above the other in laterally coextensive relation, all having one side edge extending along and coincident or flush with the side edge 76 of the wider strip 70. The several narrower strips 71-77 may be of generally equal length, and may be superposed one over the other in staggered or stepped relation, each successive upper strip having its leftward end spaced rightward from the leftward end of the next adjacent lower strip. Also, the several narrower strips may be spaced rightward from the leftward end of the lowermost, wider strip 70. A core, roll or mandrel 78 may be formed with a longitudinally extending, radially outwardly opening slot 79 adapted to receive the leftward, free end portion 80 of the lower most, wider strip 70. This is the condition shown in FIGS. 4 and 5. The cylindrical mandrel or core rod 78 may be rotated or rolled, generally clockwise as seen in FIG. 4 to wind the strips 70-75 about the mandrel, as shown in FIG. 6. Thus, the several strips 70-75 are tightly wound about the mandrel, each strip 71-75 having its entire radially outer surface in facing engagement with the next outer strip, except for the radially outer end portions. Also, the relatively wide strip 70 is spirally wound with its radially inner surface along its side edge 76 in intimate facing engagement with the next adjacent narrower strip 71, except for the innermost end region of the wider strip. In such configuration, each strip 70-75 defines a spiral having its adjacent convolutions spaced apart by the remaining strips. In particular, the spiral convolution defined by the wider strip 70 is illustrated as extending angularly approximately 500°, to define a partial second convolution of approximately 140°. The overlapping portions of convolutions of strip 70 are spaced apart a constant distance by the interposed laminations of narrower strips 71-75. The wound assemblage of FIG. 6 may be fixedly secured together in its wound or spiral configuration by any suitable means, such as a weld 81 on the outer periphery of the spiral winding, say securing together the end portions of the several strips 70-75 to prevent unwinding of the strips. From FIGS. 6 and 7 it will be understood that a scroll element is provided, generally designated 85, fabricated of the several laminations 70-75 wherein the laminations 71-75 and the adjacent portions of lamination 70 are all in overlying facing engagement with each other having one edge generally coplanar and combine to define an end wall or plate 86 generally normal to and closely surrounding the mandrel or core 78. The mandrel or core 78 may be longitudinally withdrawn for removal to leave a central opening 87, which may be suitably filled or closed, as desired. The remaining portion of lamination 70 extends beyond the end wall 86 and has its edge 77 generally coplanar and located beyond the strips or layers 71-75 of end wall or plate 86. By this extension of relatively wide strip or sheet 70 beyond the relatively narrow laterally coextensive sheets or strips 71-75, the wider strip 70 defines a spiral wrap 90 outstanding from the end wall 86. A pair of such scroll elements 85 may be arranged with their end walls 86 in parallel spaced, facing relation and their spiral wraps 90 in interfitting relation, and mounted for relative orbital motion to provide a scroll type fluid displacement apparatus. Of course, the laminations 71-75 may be more or less in number and of any preferred thickness to achieve a desired spacing between convolutions or partial convolutions of the spiral wrap 90. Also, the spiral wrap may be of more than one lamination, if desired. For example in FIG. 8, a scroll element 85a is similar to the scroll element 85 including a plurality of relatively narrow laminations 71a, 72a, 73a, 74a and 75a spirally wound with adjacent convolutions in facing engagement with each other. Additionally there may be a plurality of relatively wide laminations 70a, 70a', 70a" in facing engagement with each other and spirally wound together with the narrow laminations. The wide laminations may have one longitudinal edge generally coplanar with each other and the outer longitudinal edges of the narrow laminations. That is, the wide laminations 70a, 70a' and 70a" may have their respective edges 76a, 76a' and 76a" generally coplanar or flush with each other and with the outer edges of the narrow laminations 71a, 72a, 73a, 74a and 75a. As the laminations 70a, 70a' and 70a" are wider than the narrow laminations, they extend beyond the latter to terminate at 77a, 77a' and 77a", beyond the narrow laminations. Thus, it will be appreciated that the multiple laminations 70a, 70a' and 70a" define a spiral wrap, generally designated 90a on an end plate or wall 86a corresponding to the spiral wrap 90 of FIG. 7 on the end plate or wall 86. In addition, the spiral wrap 90a may have its intermediate lamination 70a' terminating at an edge 77a' short of the edges 77a and 77a" of laminations 70a and 70a". In this manner, the edges 77a, 77a' and 77a" combine to define an end groove, as for receiving a sealing element 91a for sealing engagement with a complementary scroll element. Also, scroll element 85a of FIG. 8 illustrates the central opening 87a as closed by a generally flat plate or wall 92a suitably secured by welds 93a to the flush or coincident edges of the several laminations. If desired, a generally flat, but spirally configured sheet or plate 94a may be suitably secured on the inner coincident edges of the narrower laminations 71a, 72a, 73a, 74a and 75a, as for bearing engagement with the seal element of a mating scroll element. From the foregoing, it is seen that the present invention provides a scroll type fluid displacement apparatus and method of manufacture which are extremely simple and advantageous in construction and operation, and fully accomplish their intended objects. Although the present invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is understood that certain changes and modifications may be made within the spirit of the invention.
The disclosure concerns a method of manufacturing scroll expander and a scroll compressor including winding together strips of different width so that the wider strip forms a scroll or spiral and the narrower strip partially occupies the inter-convolution spaces of the wider strip.
5
BACKGROUND OF THE INVENTION The invention relates to a storage device for recording media that have a flat form, such as magnetic tape cassettes and compact discs. A typical device for storing such recording media is shown in U.S. Pat. No. 3,836,222. The '222 device comprises a grid-like framework relative to which slider members can be moved. Each slider member consists of a block that is guided on the framework and is screwed to a plate. On the plate in the area inside the framework is mounted a part of a locking mechanism, in front of which a box-like component, having a front wall, is fastened on the plate. On this box-like component there is hinged a pocket having an extension piece which projects into a free space provided in the framework and, when the slider member is ejected, runs up a crosspiece of the framework and as a result pivots the pocket. One problem with the '222 device is that it requires a great deal of space in relation to the size of the recording media to be stored and, because of its complicated construction, can be manufactured only at considerable expense. A problem with other existing devices, such as that described in German Patent Document No. PS 22 48 408, is that such devices require a certain amount of dexterity when being used. This is a significant disadvantage when the device is to be used by the driver of a motor vehicle. SUMMARY OF THE INVENTION The present invention solves these problems and provides other benefits. The present invention is suitable for use by a driver while driving a motor vehicle without distracting the driver's attention. At the same time, the device of the present invention requires a minimum amount of space and can be manufactured economically from a small number of components. Broadly, the container of this invention may be defined as follows: A storage device for flat recording media comprising: (a) a housing having a bottom wall, a top wall, two elongate side walls, a rear wall, and an open front side; (b) a slider member for receiving at least one recording medium, the slider member being movably mounted in the housing and having a base portion and a front wall; (c) means for biasing the slider member to an open position out of the housing; (d) means for locking the slider member to a closed position within the housing against the bias of the biasing means; and (e) lifting means for supporting and engaging underneath the recording medium, said lifting means when the device is in the open position raising the recording medium to a lifted position away from the base portion of the slider member and above the front wall of the slider member so that the recording medium is accessible for removal and insertion. BRIEF DESCRIPTION OF THE DRAWINGS To facilitate further discussion of the invention, the following drawings are provided, in which: FIG. 1 shows a plan view, partly broken-away, of a first embodiment, intended for accommodating three magnetic tape cassettes; FIG. 2 is a view taken along line 2--2 of FIG. 1; FIG. 3 ls a plan view of the lifting element of this embodiment; FIG. 4 is a perspective view of a second embodiment; FIGS. 5 to 7 are sectional views of variants of the lifting element actuation means; FIG. 8 shows a sectional view of a further embodiment; FIG. 9 is a view of a section parallel to the front wall of the device according to FIG. 8; FIG. 10 shows a further embodiment, shown in an almost opened state (FIG. 10a) and in a completely opened state (FIG. 10b); FIG. 11 shows a cut-away plan view of a device of this invention for the storage of compact discs; FIG. 12 shows a plan view of the associated slider member; FIG. 13 shows a sectional view of part of the arrangement of receiving platters in the storage position; FIG. 14 shows, analogously to FIG. 13, the removal position; and FIG. 15 shows a side sectional view of the device when open. DETAILED DESCRIPTION OF THE INVENTION The device according to FIGS. 1 to 3 comprises an outer housing 10 having a substantially slab-like basic form. The housing has a top wall 12, a base wall 14, a rear wall 16, and side walls 18 and 20. The side of the housing opposite the rear wall forms an open front face. Rails 22 extend along the base wall, parallel to the side walls, from the rear wall 16 to the open face of the housing. The rails 22 define a guide path for the sliding movement of a slider member 24, which comprises a rear plate 26, a base plate 28, and a front plate 30. Two parallel slots 32 extend from the rear plate 26 to the front plate 30 and divide the base plate into three separate platter elements. The inner edges of the outer platter elements are stepped, as shown at 34, and the rails 22 engage over the steps and thus retain the slider member. A helical pressure spring 36 clamped between the rear wall 16 of the housing and the rear plate 26 of the slider member biases the slider member in the discharge direction, that is, the position shown in FIGS. 1 and 2. Stops are formed integrally with the base plate 28 of the slider member at the housing end, which stops slide in slots 38 in the base wall 14 of the housing and limit the outward travel. In its storage position, that is, when it is inside the housing, the slider member is held against the bias of the spring 36 by means of locking means. For this purpose, a detent 40 on the underside of a key 42 is formed integrally with the base plate of the slider member. The key 42 is defined by a slot 44, which extends through the front plate 30 into the relevant platter element of the base. The portion 46 acts as a leaf spring that is connected with the rest of the base plate 28 by connection portion 48. This leaf spring also carries the actuating button 50, which lies approximately in the plane of the front plate 30. By means of this button the user can lift the detent 40 out of a complementary recess 41 in the base wall of the housing, whereupon the slider member is pushed out by the pressure spring 36. The actuating button 50, together with the front plate 30 of the slider member, substantially close the open face of the housing when the slider member is pushed in and locked. The rear plate 26 of the slider member does not extend across the whole width of the housing and a free space is left on each side. Before the slider member is mounted in the housing, a frame piece 52 is attached to it. Its construction can be seen in FIG. 3. The frame piece 52 comprises a cassette lifting element 54 having upwardly project lateral rims 56, the outer faces of which are at a distance from one another that is slightly smaller than the internal width of the housing between its side walls 18 and 20. From the ends of these rims inside the housing there extend inwardly toward one another hook portions 58 which are at a predetermined distance from the transverse end edge 60 of the lifting element. The gap so defined allows the frame piece 52 to be placed over the ends of the rear plate 26 of the slider member in such a manner that the lifting element can be moved to the removal position in which the lifting element 54 is pivoted upwards and outwards as in FIG. 2. ln that position the rims 56 rest against the front edge of the top wall 12 of the housing. ln the storage position, the lifting element 54 is substantially parallel to the base plate 28 of the slider member. Resilient elements bias the lifting element 54 towards the pivoted-out position. Two metallic leaf springs 62 are positioned in complementary recesses 64 in the base plate 28 of the slider member and press against the underside of the lifting element 54. Lifting element 54 has projecting ribs 66 to prevent the leaf springs 62 from becoming displaced Leaf springs 62 typically are made from metal. It is, of course, also possible for the leaf springs 62 to be made of plastic material and integrally molded with the other components of the device. However, because the springs are permanently deflected when the device is closed it would be necessary to use a plastic material having no tendency for cold flow. That would cost more than the use of metal springs. The foregoing is true for the ejection springs 36. On the upper side of the lifting element there are constructed upwardly projecting stops 70, against which the cassettes, such as three cassettes 76, can be supported. ln order that the tape winding hubs of the cassettes 76 are secured against turning when in the storage position, the base plate 28 of the slider member has upwardly projecting retaining lugs 72. The lugs extend through holes 74 aligned with them in the lifting element 54 and into the winding hubs when the lifting element is depressed. When the slider member is in the outward position, the cassettes are lifted with their outer ends above the level of the free edge of the front plate 30. At the same time the winding hubs come free of the retaining lugs so that the cassettes can be removed from the front. Little dexterity is required to replace the cassettes, as they can simply be placed onto the lifting element. Then the front plate 30 of the slider member is pushed into the outer housing. This causes the rims 56 to be pressed downwards by a wedge action against the front edge of the top wall 12 of the housing. The device according to FIGS. 1-3 has been described very thoroughly, with regard to certain details, such as guides, stops, and ejection springs. Therefore, only the particular characteristic details of the other embodiments are described. ln the device of FIG. 4, unlike that of FIGS. 1 to 3, the slider member is constructed for the accommodation of two magnetic tape cassettes, for example, standardized video cassettes. The lifting element 80 is provided with a separating bar 81. The locking arrangement is located approximately in the center of the front plate of the slider member. ln addition, the slider member is guided by means of its side plates 82 on the side walls of the housing rather than the rail arrangement on the base of the housing of the embodiment according to FIGS. 1-3. FIGS. 5 to 7 illustrate three ways of actuating the lifting element 80 to a position in which the cassettes can be easily inserted and removed. In FIG. 5, the lifting element is connected to the slider member 84 by means of a pivot joint 83 and a leaf spring 79. Leaf spring 79 is fastened at one end to the base of the slider member and presses with its other, free end against the lifting element, thereby pressing the free end of the lifting element upwardly. The cassettes rest against a stop 88. In FIG. 6, a free edge 85 of an internal wall 86 of lifting element 80 contacts an inwardly projecting bar 87 on the housing. As a result, the lifting element is pivoted about its pivot bearing 83. In FIG. 7, a biasing spring is provided for the lifting element in the form of a torsion coil spring 89 having two leg sections or wire ends. One leg is supported on the base of the slider member and the other leg is supported against the bottom of the lifting element 80. The lifting angle is limited by stop pins 90, which extend from the sides of the lifting element into openings 91 in the side plates 82 of the slider member. Stop pins 90 come to rest against the upper end edge of those openings. FIGS. 8 and 9 show a variant of FIG. 6. ln a double housing 200, a double slider member 202 is guided in grooves 201, which are located in the horizontal plane of symmetry of the housing. Extending from a central plate 204 of the slider member are pairs of lateral bearing blocks 203 and 203'. In the upper bearing blocks 203, a lifting element 205, analogous to the lifting element 80 in FIGS. 4 to 7, is mounted such that it can be pivoted through a limited angle. A suspension element 206 is pivotably mounted in the lower bearing blocks 203'. Suspension element 206 comprises a platter 208 designed to accommodate one or more cassettes 207 and a suspension plate 209. Suspension plate 209 extends upwardly at a right angle from platter 208 to a pivotal engagement with bearing block 203'. The lifting element 205 is lowered by the force of gravity when the slider is pushed in. The suspension element 206 is lifted by wedge action when platter 208 hits the front edge 210 of the housing. At the same time, edge 210 limits the downward pivoting movement of suspension element 206. Retaining lugs 211 are formed, in mirror-symmetrical arrangement, integrally with the central plate 204 of the slider member. When the cassette 207 on lifting element 205 is lowered, the retaining lugs 211 engage through openings 212 in the lifting element. The lower retaining lugs are free to pass from above through the tape winding hubs in cassette 207 on the suspension element 206. A double front plate 213 is provided at the outer end of the central plate 204 of the slider member. Stops 214 prevent the cassettes from slipping. The embodiments described are devices for storing magnetic tape cassettes. The following two embodiments are used for accommodating records or video discs, and especially for storing standardized, so-called "compact discs." Because these discs are very thin in relation to their diameter, the space in the interior of the housing is best utilized when the discs are closely packed together when in the housing. The discs are presented for convenient removal when the discs are out of the housing. The embodiment shown in FIGS. 10a and 10b comprises a slider member 301, which can be pushed out of and into a housing 300. On each side of front plate 309 of the slider is hinged a pair of guide bars 302. Guide bars 302 are pivotable about axes 303 and extend parallel to the front plate 309 of the slider member when the slider member is withdrawn from the housing member. The relationship of the distance between the pairs of axes 303 to the length of the guide bars 302 is such that when the slider member is withdrawn from the housing both guide bars are free to pivot upwardly. However, in the storage position, the guide bars are pivoted inwardly so that an uppermost disc-holder 304 will still fit underneath top wall 305 of the housing. The free ends of the quide bars are hinged to uppermost disc-holder 304 at the same axial spacing the other ends of the guide bars are spaced on the slider member. The other disc-holders 306, 307, and 308 are hinged to guide bars 302 through axes. Although the spacing between the axes is constant, the distance between the pivot axes and the front plate 309 of the slider member increases from right to left in FIG. 10a. In the open position the lowermost disc-holder 308 extends into the housing 300. Actuator extensions 312 of disc-holder 308 project laterally from the disc-holder, close to the open front of the housing. Extensions 312 engage behind guide ribs 311, which project inwardly from side walls 310 of the housing. As soon as the actuator extensions 312 contact the guide ribs 311 when the slide is ejected, the actuator extensions 312 slide upwardly along the guide ribs 311. The parallelogram arrangement is formed by the guide bars and the disc-holders hinged thereon in the unfolded position according to FIG. 10b. In the unfolded position, the individual disc-holders are sufficiently spaced apart for the compact discs 313 lying on them to be accessible from above and pushed forward with the fingers. If desired, the disc-holders can be provided with a cut-out portion at the front for access to the discs. In addition, the holders are stepped backwards to further facilitate access to the discs. In FIGS. 11-15 a slider member 101 is slidably movable in the housing 100. For this purpose, the slider member comprises two base plates 109 and 110, which are connected to one another at the front of the slider member by a front plate 111 and at the rear by a rear plate 108. A step 102 projects from both base plates into the empty space 128 between these plates. Two guide rails 103 project inwardly from the housing base 129 and engage over these steps. The base plates 109 and 110 are reinforced by upright side edges 112. These edges, near the inner end of the slider member, become cheeks 113, which are joined to lugs 107. The lugs extend at right-angles to the cheeks. The height of cheeks 113 and the lugs 107 is substantially the height of the interior of the housing, as shown in FIG. 15. Helical pressure springs 106 are supported at one end against rear wall 131 of the housing and at the other end against the lugs 107. Springs 106 force the slider member out of the housing. In its insertion position, the slider member 101 is secured by a catch 105, which locks into a recess 130 in the housing base 129. The catch 105 is integrally formed with a spring button 104 and can be released by raising button 104 with the finger. Because the slider member is made of resiliently deformable plastic material, the spring button 104 can be readily separated from the material of the base plate 109 by means of the slits 104a shown in FIG. 12. The extent to which the slider member can be ejected is limited by stops which co-operate with counter stops in the housing (not shown). Bearing pins 11 of receiving platters 114 for respective compact discs 125 are accommodated in bearing apertures 132 in the cheeks 113. A total of five receiving platters are arranged one above the other The individual receiving platters 114 differ from one another in the shape and position of their lever arms 116, 120, 121, 122, and 123. The lever arm 116 of the uppermost receiving platter 114 extends substantially over the width of the slider member between the springs 106. At the end of lever arm 116 are two pegs or hooks 117 which project lateraly. Onto each hook 117 is hooked a tension spring 118. The other ends of the tension springs 118 are anchored in lugs 119, which project upwardly from the base plates 109 and 110 of the slider member. Accordingly, if the slider member 101 is unlocked and ejected from the housing 100 by the springs 106, a torque produced by the biasing of the springs 118 acts on the lever arm 116 and the uppermost receiving platter 114 is swung into the position shown in FIG. 15. During this swinging movement, the other receiving platters are spread out as a result of the lever arm 116 of the uppermost platter acting on the lever arms 120, 121, and 122, arranged next to one another in a staggered configuration. Lever arms 120, 121, and 122 are activated by lever arm 116. Because the lever arms are of different lengths, their angle of spread is correspondingly smaller than that of the uppermost platter 114. For the lowest receiving platter, the lever ratios for operation by the lever arm 116 are unfavorable. Therefore, the lever arm 123 is activated, not by the lever arm 116, but by the lever arm 122 arranged above it (FIG. 14). The three lowest receiving platters have cut-out portion 124 so that there is room for the tension springs 118. The records are held securely in position by means of central hub projections 126. The records can be raised by gripping them in the area of the front cut-out portions 127 of the receiving platters. A supporting rim 133 of the receiving platters defines their distance from one another in the storage position. Variations and modifications will be apparent to one skilled in the art, and the claims are intended to cover all variations and modifications that fall within the true spirit and scope of the invention.
A storage device for flat recording media, e.g., compact discs, is disclosed. The device comprises a housing and a slider member having a base portion and front wall that covers the open front face of the housing when the slider member is inserted. A lifting element, which is transported out of the housing by means of the slider member, is provided for supporting the recording media in a position for easy insertion and removal.
8
FIELD OF THE INVENTION [0001] The present invention relates to rope ladders and a method of securing the steps in position. BACKGROUND OF THE INVENTION [0002] Rope ladders have long been used in a variety of different applications. The use of rope ladders to escape through a window when the conventional exit route is blocked was disclosed as long ago as 1865 in U.S. Pat. No. 50,596. The present marketplace provides a variety of ladder products intended as escape ladders. Rope ladders have also been used in various shipboard applications and as rescue ladders in helicopters and the like. More recently, the rope ladders has become a popular piece of playground equipment since learning to climb is an important developmental step. Rope ladders provide a climbing challenge to children as the ladder may move with each step taken. [0003] Rope ladders typically comprise a series of rigid or semi-rigid rungs which are attached at spaced intervals to a pair of ropes. [0004] There are many patents directed to collapsible ladders. For example, U.S. Pat. No. 6,382,352 discloses a Kevlar™ type fire escape ladder with PVC rungs that has a weighted bottom step. U.S. Pat. No. 4,702,347 discloses a folding, burglarproof fire escape ladder. U.S. Pat. No. 4,127,184 discloses a combination plant box and escape ladder. [0005] Several patent have addressed the problem of how to attach the platform or rung to the flexible vertical member. U.S. Pat. No. 4,442,920 discloses a ladder in which rope segments are placed in open-ended notches disposed in the platforms and are then clamped into position. In U.S. Pat. Nos. 4,241,809 and 4,554,996 a pair of wedge collars is used in cooperation with each step. A wedge collar is disposed below each of the through openings bearing up against the step. U.S. Pat. No. 4,683,981 also discloses a generally diamond-shaped wedge heart. U.S. Pat. No. 2,990,908 is directed to the use of a knot placed before and after each rung for proper positioning. This is time consuming and not amenable to mass production. [0006] U.S. Pat. No. 4,475,628 is directed to an embarkation/debarkation net. The net includes securing elements which comprise a pair of perpendicularly crossed tubular elements. The tubular elements may be tubes of heat shrinkable material. The purpose of the tubular elements is to maintain the components of the net in spaced orientation and it requires a cross of elements to be effective. [0007] Another way in which ladder rungs have been held in position is by passing the rope through an opening in the rung and then around and over the outside of the rung where it is stapled in position. This type of configuration can be seen, for example, in the playground rope ladder marketed by Walnut Grove Fence and Playground as the C-26R Heavy Duty Ladder. See www.walnutgrove.com. Potential drawbacks of this method are the cost of extra rope and staples and the time required to position the rungs. [0008] Although rope ladders have been in use for a long time, there remains a need for a ladder that is secure and easy to assemble. The present invention addresses the problems associated with the prior art methods of securely maintaining the rungs in position. SUMMARY OF THE INVENTION [0009] The present invention provides a rope ladder in which the rungs can be positioned in place quickly and securely. The ladder is useful in a variety of situations. The flexible ladder of the present invention is particularly useful as a climbing apparatus for a playground. [0010] The ladder is designed so that the rungs resist slippage when downward pressure is applied. [0011] In one aspect of the invention, there is provided a flexible ladder having: [0012] i) a plurality of steps, each step having a horizontal support surface and two bores, one of said bores at each end of said horizontal support surface; [0013] ii) at least two spaced-apart flexible vertical members, each of said flexible spaced-apart members passing through one of said bores in said support surface; and [0014] iii) a stop member encircling each of said flexible vertical members thereby providing a downward stop for each step. [0015] In a preferred embodiment, the stop member is a length of heat-shrinkable tubular sleeving positioned on said flexible vertical member. [0016] In another preferred embodiment, the steps comprise a plurality of platforms, each platform selected from the group consisting of a dowel, a length of plastic, PVC or metal tubing and a wooden or synthetic slat. [0017] In yet another preferred embodiment, the flexible vertical member is a length of flexible material which may comprise a rope, a strap, a cable, a chain or the like. [0018] In another aspect of the invention, a method of assembling a rope ladder is provided. The method comprises threading a rope or other type of flexible member sequentially through a bore in a step and then a heat-shrinkable tube. The steps and the sleeves are held in predetermined spaced positions. The sequential threading is continued until the desired ladder length is achieved. Heat is then applied to shrink the sleeves so that they are held in position on the rope. [0019] In an alternative method of the present invention, the flexible members are held in position vertically and a dowel is positioned over the rope so that the bore of the dowel lines up with the rope and then the dowel slides down the rope to a predetermined position. Next a heat-shrinkable sleeve is slid down the rope until it comes to a rest at the dowel. BRIEF DESCRIPTION OF THE DRAWINGS [0020] Preferred embodiments of the invention are described below with reference to the drawings in which: [0021] [0021]FIG. 1 illustrates a prior art rope ladder; [0022] [0022]FIG. 2 illustrates a first embodiment of the present invention; [0023] [0023]FIG. 3 illustrates a second embodiment of the invention; [0024] [0024]FIG. 4 illustrates the rung positioning device; [0025] [0025]FIG. 5 illustrates one method of production by which the rung positioning device can be positioned on the rope; and [0026] [0026]FIG. 6 illustrates another method of making the rope ladder of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0027] Rope ladders are well known in the art. In the present invention, the term “rope ladder” refers to a flexible ladder having a plurality of platforms suspended by at least two flexible vertical members. The term “flexible vertical member” refers to a rope, a strap, a piece of cable or any other linear flexible material that is disposed vertically when in use. The term “platform” refers to any horizontal support which is used to support a person's weight as they climb the ladder. This may be a rung, a dowel, a slat, a metal or plastic step, a piece of synthetic tubing, a length of rope or the like. The flexible member typically passes through a hole or bore disposed in the platform. The platform is secured in position on the vertical member to form a step or rung. [0028] An example of a prior art playground rope ladder is illustrated in FIG. 1. The rope ladder 10 comprises a series of rungs. Each rung 12 is positioned along four nylon ropes 14 . Each rung 12 has several bores 16 , 18 . The rope is threaded through the bores and then wrapped around the rung and stapled to itself to hold the rung in position. The rope is then passed on to the next rung, threaded, wrapped around and so on. This format requires a rope length significantly in excess of the ladder length and staples and also requires substantial hands-on time. [0029] The present invention addresses the problems of the prior art by providing a novel method for holding the rungs of a rope ladder in position. Referring now to FIG. 2, a ladder 20 is provided which comprises a plurality of platforms or horizontal supports 22 positioned along vertical flexible members 24 . The flexible vertical members 24 pass through bores 26 in each horizontal support 22 . It is clearly apparent that the horizontal supports can be flat as well as round and that a slot may take the place of the bore. While three flexible vertical members are illustrated, the device can also comprise only two or more than three vertical members. The vertical members can be made from any flexible material. Preferred flexible materials include rope, nylon cord, chain, cable, strapping and the like. A stop member 28 is positioned below each horizontal support to prevent the horizontal support from slipping down the vertical member when downward pressure is applied, such as when a person steps on the horizontal support. The use of a stop member eliminates the need to wrap the rope around the dowel. [0030] [0030]FIG. 3 illustrates another embodiment of the flexible ladder of the present invention. A playground climber 30 is provided in which a lattice of horizontal supports 32 and flexible vertical members 34 are provided. The horizontal supports 32 are typically dowels with a bore 35 at each end and the vertical members are typically ropes. A stop member 36 is positioned below each of the bores 35 . The embodiment illustrated in FIG. 3 is particularly useful as a climbing apparatus for a playground. The horizontal supports may be staggered to provide a greater climbing challenge. [0031] An exemplary stop member is shown in FIGS. 4A and 4B. A heat shrinkable tube 40 is cut into predetermined lengths to provide a number of sleeves 42 . Each sleeve 42 is adapted to be threaded onto the flexible vertical member. The interior diameter of the sleeve is large enough to slide over vertical member. The sleeve 42 comprises thermoplastic material 44 which shrinks upon the application of heat. The tubular sleeve 42 shrinks to tightly encapsulate the flexible vertical member. When shrunken, the tubular sleeve has an exterior diameter 46 which is larger than the diameter of a bore in a support platform and an interior diameter 48 which is snug against a flexible vertical member. The length of the sleeve is preferably longer that the diameter. In a preferred embodiment the sleeve is 2-3 mm. thick and approximately 1 inch long. The sleeve is sufficiently tight around the rope to prevent the horizontal platform or step from sliding down when someone steps on it. In the case where the step is a slat, the sleeve is of an adequate diameter to prevent the vertical member from sliding through the slot. [0032] [0032]FIG. 5 illustrates one possible method for manufacturing the ladders of the present invention. A base 50 has a series of grooves 52 adapted to hold a dowel 54 . The dowel 54 has a bore 56 at each end. The base 50 also includes means 58 for holding thermoplastic sleeves 60 . A rope 62 is passed through the center of the sleeve 60 and through the bore 56 in the dowel 54 . Once in position, the system is heated and the thermoplastic sleeves 60 tightly encompasses the rope 62 . When in use, the heat-shrinkable sleeve 60 prevent the rope 62 from slipping through the bores 56 in the dowel 54 . A two sided press type of system where the ladder is held between two heated plates can also be used. [0033] Another way of assembling the ladder is shown in FIG. 6. The vertical members or ropes 70 are held in an upright position. A dowel 72 is slid down the rope and comes to stop against a positioning block 74 . The positioning block of the assembly device can be moved in and out of position to stop or not stop the dowel. A thermoplastic sleeve 76 is then slid down the rope and comes to rest against the dowel. The next set of positioning blocks are pivoted into position and the next dowel is slid down the ropes followed by the next thermoplastic sleeve. The process is repeated until the desired length of ladder is achieved. Heat is then applied and the thermoplastic sleeves shrink tightly around the rope. [0034] While specific embodiments have been described herein in detail, it is apparent that the basic construction can be altered to provide other embodiments not specifically described. Thus, changes in construction and applications of the invention will suggest themselves without departing from the spirit and scope of the invention. The disclosures and descriptions herein are purely illustrative and are not intended to be in any sense limiting.
A rope ladder having a plurality of steps, each step having a horizontal support surface and two bores and at least two spaced-apart ropes, each with a stop member fixed to the ropes thereby providing a downward stop for each step.
4
FIELD OF THE INVENTION The present invention relates generally to integrated circuits (ICs), and more particularly to a method for reducing silicide defects in an IC. BACKGROUND OF THE INVENTION Transistors are commonly used in integrated circuits. FIG. 1 a shows a conventional n-type metal oxide semiconductor (MOS) transistor 110 formed on an active region of a substrate 105 . A p-well 108 is located in active region of the substrate. Shallow trench isolations 180 are used to isolate the active region from other device regions. The transistor has source/drain diffusion regions 125 a - b adjacent to a gate 130 , which includes a gate electrode 131 over a gate dielectric layer 132 . Located on the gate sidewalls are dielectric sidewall spacers 160 . Metal silicide contacts 140 and 141 are provided on the surface of the substrate in the source/drain regions and gate electrode. Nickel silicide or nickel alloy silicides have been extensively used in contacts due to low sheet resistance properties. Nickel (Ni) atoms, however, are highly diffusive. During processing, Ni atoms can diffuse beneath the spacers, resulting in the formation of Ni pipes 148 . Ni pipes can lead to junction leakage, negatively affecting device performance or functionality. FIG. 1 b shows a TEM image of nickel pipes 148 . As shown, such nickel pipes can result in gate-to-source or gate-to-drain short circuits. In view of the foregoing, it is desirable to provide transistors with metal silicide contacts which reduce or minimize the formation of metal pipes. SUMMARY OF THE INVENTION The present invention relates to reducing silicide defects in ICs. In one aspect of the invention, an IC having a transistor that comprises a gate on a substrate is provided. The gate has gate sidewalls. The transistor further comprises dielectric spacers disposed on the gate sidewalls and metal silicide contacts over the diffusion regions. The outer walls of the dielectric spacers are aligned with the metal silicide contacts to reduce stress on the contacts. In another aspect of the invention, a method for forming a transistor in an IC comprises the steps of providing a substrate having a gate on the substrate, the gate having gate sidewalls, and diffusion regions in the substrate adjacent to the gate. Dielectric spacers are formed on the gate sidewalls. Metal silicide contacts are formed over the diffusion regions. The outer walls of the dielectric spacers are aligned with the metal silicide contacts to reduce stress on the contacts. In another aspect of the invention, a method for reducing formation of metal pipes is disclosed. The method includes providing a feature on a substrate and forming dielectric spacers on sidewalls of the feature. Metal silicide contacts are formed on the substrate adjacent to the dielectric spacers, wherein outer walls of the dielectric spacers are aligned with edges of the metal silicide contacts. By aligning the outer walls of the dielectric spacers with edges of metal silicide contacts, formation of metal pipes is reduced. These and other objects, along with advantages and features of the present invention herein disclosed, will become apparent through reference to the following description and the accompanying drawings. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. Various embodiments of the present invention are described with reference to the following drawings, in which: FIGS. 1 a - b show a conventional transistor with metal pipes; FIG. 2 shows a transistor in accordance with one embodiment of the invention; and FIGS. 3 a - h show a process for forming a transistor in accordance with one embodiment of the invention. DESCRIPTION OF THE INVENTION The present invention relates to ICs. More particularly, the present invention relates to a method for forming silicide contacts in ICs. In accordance with the invention, a spacer pull-back etch is performed during the silicidation process to form silicide contacts to eliminate or reduce substrate stress that may contribute to the formation of pipe defects. FIG. 2 shows a portion of an IC 200 in accordance with one embodiment of the invention. The portion includes a transistor 210 formed in an active region 208 in the substrate 205 . The active region is isolated from other device regions by, for example, shallow trench isolations (STIs) 280 . In one embodiment, the substrate comprises a silicon substrate, such as a lightly doped p-type substrate. Other types of substrates, such as silicon on insulator (SOI) or silicon germanium, are also useful. The depth of the STIs should be sufficient to reduce or minimize leakage or punch-through. Typically, the depth of the STIs is about 2000-6000 Å. The substrate comprises a well heavily doped with dopants of a second polarity type. The second polarity type comprises, for example, p-type. Doping the well with n-type dopants is also useful. The depth of the well is typically about 1-12 μm below the STIs. The transistor comprises a gate 230 a on the substrate. The gate includes a gate electrode 231 over a gate dielectric 232 . Typically, the gate electrode is formed from polysilicon and the gate dielectric is formed from thermal oxide. Other types of materials are also useful. Source/drain diffusion regions 225 a - b are located adjacent to the gate beneath the substrate surface. The source/drain diffusion regions are heavily doped with dopants of a first polarity type. The first polarity type, for example, comprises n-type, forming a n-type transistor. Forming p-type transistors with p-type dopants as the first polarity type is also useful. As shown, a gate 230 b is also provided over one of the STIs. Typically, a gate comprises a gate conductor that extends into various active and inactive regions (e.g., STIs) of the substrate. Other circuit arrangements are also useful. Dielectric spacers 260 are disposed on the gate sidewalls. The dielectric spacers, for example, are formed from silicon nitride. Other types of dielectric materials are also useful. Contacts 240 and 241 are provided over the diffusion regions and gate electrodes. In one embodiment, the contacts comprise metal silicide. The metal silicide, for example, comprises nickel, platinum, gold, or a nickel alloy, such as nickel-platinum. Other metal silicides are also useful. In accordance with one embodiment of the invention, the outer surface of the dielectric spacers is in alignment with the metal silicide contacts. Aligning the outer surfaces of the dielectric spacers with the silicide contacts avoids the formation of spacer material over the silicide contacts. This has been found to reduce stress on the metal silicide contacts during processing. Additionally, aligning the spacers with the contacts has also been found to reduce stress in the divot area 182 at the corner of the STI during processing. Reducing stress on the divot areas of the STI and on the metal silicide contacts reduces or prevents the formation of metal pipes. FIGS. 3 a - h show a process for forming an IC 300 in accordance with one embodiment of the invention. Referring to FIG. 3 a , a semiconductor substrate 305 is provided. The substrate, in one embodiment, comprises a p-type silicon substrate. Other types of substrates, such as a germanium-based, gallium arsenide, silicon-on-insulator (SOI), or sapphire substrate, are also useful. The substrate is prepared with an active region 308 . The active region comprises a well heavily doped with dopants of a second polarity type. To form the active region, conventional ion implantation techniques, such as implantation with a mask can be used. Other techniques for forming the active region are also useful. Isolating the active regions from other device regions on the substrate are isolation regions 380 . The isolation regions, for example, comprise STI regions. The depth of the STIs should be sufficient to prevent leakage or punch through. Typically, the depth of the STIs is about 2000-6000 Å. Various conventional processes can be employed to form the STI regions. For example, the substrate can be etched using conventional etch and mask techniques to form trenches which are then filled with dielectric material such as silicon oxide. Chemical mechanical polishing (CMP) can be performed to remove excess oxide and provide a planar substrate top surface. The STI regions can be formed, for example, prior to or after the formation of the doped wells. Referring to FIG. 3 b , the process continues to form the gate layers on the substrate. For example, forming the gate layers comprises sequentially forming a gate dielectric layer 332 and a gate electrode layer 331 on the substrate surface. In one embodiment, the gate dielectric layer comprises thermal oxide. Other types of gate dielectrics are also useful. The gate electrode layer, for example, comprises polysilicon. Other types of gate electrode materials, for example, metals such as Al, are also useful. The gate layer, in one embodiment, can comprise a heavily doped polysilicon layer of a first polarity type. The polysilicon can be in-situ doped or doped by ion implantation after deposition. Providing undoped polysilicon is also useful. Referring to FIG. 3 c , the layers are then patterned using conventional mask and etch techniques to form gates 330 a - b . As shown, gate 330 a is formed in the active region while gate 330 b is formed over a STI. Source/drain diffusion regions 325 a - b are formed in the active region of the substrate adjacent to the gate 330 a , as shown in FIG. 3 d . The diffusion regions, for example, comprise heavily doped regions of the first polarity type. The doped regions can be formed by ion implantation. Spacers 360 , as shown in FIG. 3 d , are formed on sidewalls of the gates. The spacers comprise, for example, a dielectric material. In one embodiment, the spacers comprise silicon nitride (SiN). Other dielectric materials including, for example, silicon dioxide, oxide-nitride-oxide (ONO) stacks, TEOS or silicon oxy-nitride (SiO x N y ) are also useful. Conventional processes may be employed to form the spacers. For example, the dielectric layer can be blanket deposited over the substrate, covering the transistors and the substrate. The layer can be deposited by, for example, chemical vapor deposition (CVD). A spacer etch is then performed to form the spacers. The spacers can be formed using an anisotropic etch, such as reactive ion etch (RIE) or dry etch. In one embodiment, the diffusion regions comprise lightly and heavily doped regions. Typically, the light doped regions are formed by a first ion implantation process before spacer formation. After spacer formation, a heavily doped region is formed by a second ion implantation process. Other types of techniques for forming the diffusion regions are also useful. Referring to FIG. 3 e , a pre-silicide clean is performed. The pre-silicide clean, for example, comprises wet cleaning using DHF in a dilute aqueous solution. Other clean chemistries or processes are also useful. The pre-silicide clean prepares the substrate for metal deposition by removing native oxide on the gate and source/drain diffusion regions. The clean process forms undercuts 364 in the bottom of the spacers. As shown in FIG. 3 f , a metal layer 345 is deposited over the substrate, covering the diffusion regions and gate. Preferably, the metal layer comprises nickel, platinum, gold or a nickel alloy, such as nickel platinum. Other metals are also useful. Typical thickness of the metal layer is about 10-1000 Å. Other thicknesses are also useful. A cap layer 346 is deposited over the metal layer. The cap layer prevents oxidation of the metal layer. The cap layer comprises, for example, titanium nitride (TiN). Conventional deposition techniques, such as sputtering, are used to form the metal and cap layers. Referring to FIG. 3 g , a salicide process is performed to form metal silicide contacts 340 and 341 over the diffusion regions and the gate electrode. In one embodiment, the salicide process forms nickel or nickel alloy silicide contacts. The salicide process, for example, comprises annealing the substrate, causing a reaction between the metal and silicon (e.g., substrate, epi and polysilicon). Typically, the salicide process comprises rapid thermal annealing (RTA). In one embodiment, annealing is conducted in one step at a temperature of about 300-400° C. for about 1-1000 sec. Unreacted metal and cap material are then removed, for example, by wet cleaning using a sulfuric peroxide mixture (SPM) or an ammonium peroxide mixture (APM). As shown, a portion of the spacers overlays the metal silicide contacts due to the presence of the undercuts in the bottom of the spacers. Referring to FIG. 3 h , the outer walls of the spacers are reduced or pulled back. In one embodiment, the spacers are pulled back to be in alignment with the silicide contacts, as indicated by dotted lines and arrows. Pulling back the spacer outer walls avoids any spacer material overlaying the silicide contacts. In one embodiment, pulling back of the outer walls of the spacers is achieved with an anisotropic etch, such as RIE or dry etch. Preferably, the spacer pull-back etch is highly selective to the silicide contacts and STI. In one embodiment, the spacer pull-back etch employs a CH 2 F 2 /Ar/O 2 or CHF 3 /Ar/O 2 chemistry, and is performed at a temperature of about 1-150° C. and a pressure of about 5-45 mTorr. Under such conditions, SiN-to-Si or SiN-to-oxide etch selectivity of more than about 10:1 can be obtained. Other etch chemistries or techniques of pulling back the spacers are also useful. Pulling back the spacers also advantageously removes residues at the STI corners. An additional dry and/or wet clean may be performed to remove etch residues. In one embodiment, a second annealing step is performed after the spacer pull-back etch in order to lower the resistance of the silicide contacts. For example, nickel-rich nickel disilicide (NiSi 2 ) formed after the anneal prior to spacer pull back is converted to the lower resistivity nickel monosilicide (NiSi) phase in this step. In one embodiment, the second annealing step is conducted at a temperature of about 400-600° C. for about 1-1000 sec. As described, the formation of the silicide contacts comprises, in one embodiment, first and second RTA processes. The use of more than one RTA step facilitates the formation of the desired silicide phase to achieve lower contact resistance. For example, a first annealing step is conducted at a lower temperature to form nickel-rich silicide, followed by a second annealing step at a higher temperature to form nickel monosilicide which has lower resistivity. In one embodiment, as described, the spacer pull back etch is performed in-between the two RTA processes. This avoids stress on the silicide contacts during the second annealing step. Alternatively, the spacer pull-back etch may be performed after the second annealing step. The process continues by forming interconnections to the contacts of the transistors. For example, a dielectric is deposited and patterned to create vias and trenches. The vias and trenches are then filled with conductive material, such as copper, to form interconnects. Additional processes are performed to complete the IC, for example, additional interconnect levels, final passivation, dicing, and packaging. The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments, therefore, are to be considered in all respects illustrative rather than limiting the invention described herein. Scope of the invention is thus indicated by the appended claims, rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are intended to be embraced therein.
A method for forming silicide contacts in integrated circuits (ICs) is described. A spacer pull-back etch is performed during the salicidation process to reduce the stress between the spacer and source/drain silicide contact at the spacer undercut. This prevents the propagation of surface defects into the substrate, thereby minimizing the occurrence of silicide pipe defects. The spacer pull-back etch can be performed after a first annealing step to form the silicide contacts.
7
This invention relates to a foundry machine for forming molds or cores by an automated process. In foundry molding machines wherein molds or cores for use in subsequent casting operations are formed out of molding materials such as sand, it is common to place onto a vertically movable work table the upper and lower cavity-containing mold halves, known as the cope and drag, respectively. The table is movably mounted in a fixed frame, the upper portion of which contains a sand hopper, appropriate valving, and a blow head and blow plate adapted to blow sand downwardly into the mold cavity. The table is adapted to lift the stacked mold boxes into communication with the underside of the blow plate for filling or charging the mold box cavity with sand, following which the mold boxes are lowered and curing means, such as a catalyzing gas manifold, are transferred into engagement with the lowered mold boxes to inject a sand-curing gas into the mold cavity. Following this step, means are provided for vertically separating the upper and lower mold boxes, ejecting the newly-formed part and automatically conveying the part away. An exemplary prior art patent showing such construction is U.S. Pat. No. 4,100,961 to Goss et al. The above-mentioned prior art Goss patent describes a variety of techniques which have been employed for ejecting the finished part from the mold boxes. One of the methods involves separating the molds and then inverting the mold box which initially retained the finished part and ejecting the part downwardly from the inverted box onto a transfer device. Another technique therein described involves separating the mold boxes, moving the finished part upwardly out of the lower mold box on ejector pins, moving a fork transversely into the space between the lower mold box and temporarily elevated part, and then lowering the ejector pins to deposit the part onto the fork, which can then be transversely withdrawn. Still another disclosed technique involves separating the molds while retaining the formed part in the upper mold half, transversely moving a conveyor or fork-type device into the space beneath the downwardly-facing upper mold cavity and ejecting the part downwardly onto the conveyor for removal. It would be highly desirable to further automate the operating cycle of a foundry machine to include automatic means for initially loading the mold boxes onto the work table and for removing them therefrom following a production run. Furthermore, associated tooling unique to a given finished part may include, in addition to the cope and drag, an underlying bottom stool containing a lower ejector mechanism, an upper ejector mechanism, a gassing manifold, a blow plate and a sand magazine. It would be highly desirable to further automate the operating cycle by providing means for automatically loading such additional associated tooling into the foundry machine, without the need for manual placement or securing of these components. SUMMARY OF THE INVENTION According to one aspect of the invention, the mainframe of the foundry machine is provided with a work table which supports the tooling during portions of the operating cycle and additional tooling support means which support the tooling during other portions of the cycle. Such additional tooling support means include means for separating the upper and lower mold boxes following formation of a part within the mold box cavities. A stationary tooling loading table is provided adjacent to the mainframe and work table, and includes tooling transfer means for moving the tooling to and from the additional tooling support means mounted in the mainframe. Part-removal means are also provided for removing a finished part which has been ejected from the separated molds. According to a further aspect of the invention, the tooling is conveyed along rails on the auxiliary table and then onto aligned rails which form a portion of the additional tooling support means in the mainframe. The work table then lifts the tooling off of such mainframe rails, and these rails are swung into an inactive position where they avoid interference with the vertically moving table and tooling. A further aspect of the invention involves the mounting of the part-removal means on the auxiliary table, and the use of the same transfer means to both load and unload the tooling from the mainframe and to remove a completed part by means of the part removal means. Accordingly, it is an advantage of this invention to provide a fully automatic method and apparatus for initially loading tooling onto the work table and for removing such tooling therefrom after the completion of a production run. It is another advantage of this invention to provide a method and apparatus in which the tooling which is automatically loaded and unloaded from the work table may optionally include, in addition to the cope and rag, one or more of the sand magazine, blow plate, gassing manifold, top ejector means and bottom ejector means. Another advantage of this invention is the use of only a single transfer mechanism to propel both the tool-loading and unloading means and the part removal means, thereby saving expense, maintenance and space. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a front view of the foundry machine of the present invention, showing the tooling in solid lines on the loading table and in phantom lines on the work table. FIG. 2 is a left side view in the direction of arrow 2 of FIG. 1. FIG. 3 is a right side view in the direction of arrow 3 of FIG. 1. FIG. 4 is a plan view, partly in phantom, in the direction of arrows 4--4 of FIG. 1. FIG. 5 is a fragmentary plan view of a portion of the trolley and loading table. FIG. 6 is a front view of the apparatus shown in FIG. 5. FIG. 7 is a left side view in the direction of arrows 7--7 of FIG. 6. FIG. 8 is an enlarged fragmentary view in the direction of arrows 8--8 of FIG. 7, showing the pick-off finger stops. FIG. 9 is an enlarged fragmentary view in the direction of arrows 9--9 of FIG. 7, showing a position sensor for the carriage. FIG. 10 is an enlarged view of the carriage and gripper jaws, viewed in the direction of arrows 10--10 of FIG. 7. FIG. 11 is a plan view in the direction of arrows 11--11 of FIG. 10. FIG. 12 is an enlarged plan view of the gripper jaws of FIG. 11, shown in their open position. FIG. 13 is a side elevational view of the gripper jaws, viewed in the direction of arrows 13--13 of FIG. 11. FIG. 14 is an enlarged front view of the carriage transfer mechanism. FIG. 15 is a front view of the work table and related structure. FIG. 16 is a side view of the work table, viewed in the direction of arrows 16--16 of FIG. 15. FIG. 17 is a fragmentary view, similar to FIG. 16, showing the alternative positions of the rails. FIG. 18 is a side view of the rail actuator mechanism, viewed in the direction of arrows 18--18 of FIG. 15. FIG. 19 is a plan view, partly broken away, of the work table, viewed in the direction of arrows 19--19 of FIG. 16. FIG. 20 is a right side view of the tooling clamping mechanism, viewed in the direction of arrow 20 of FIG. 19. FIG. 21 is an enlarged view of the clamping mechanism shown within circle 21 of FIG. 20. FIG. 22 is a sectional view in the direction of arrows 22--22 of FIG. 21. FIG. 23 is a plan view of the work table supporting structure, viewed in the direction of arrows 23--23 of FIG. 16. FIG. 24 is a fragmentary view, similar to FIG. 16, showing the table position-indicating means. FIG. 25 is a plan view of the cope hanger mechanism, viewed in the direction of arrows 25--25 of FIG. 15. FIG. 26 is an enlarged plan view detail of one of the cope hangers of FIG. 25. FIG. 27 is a sectional elevation viewed in the direction of arrows 27--27 of FIG. 26. FIG. 28 is a front view of the cope hanger of FIG. 27. FIG. 29 is a plan view of the gassing manifold transfer mechanism, viewed in the direction of arrows 29--29 of FIG. 1. FIG. 30 is a front view of the apparatus of FIG. 29. FIG. 31 is a right side view in the direction of arrow 31 of FIG. 30. FIG. 32 is a plan view, partly broken away, of the gassing manifold, viewed in the direction of arrows 32--32 of FIG. 30. FIG. 33 is a front view partly broken away, of the gassing manifold and top ejector plate of FIG. 32. FIG. 34 is an enlarged view of the clamping mechanism within the circle 34 of FIG. 30. FIG. 35 is a front view of the top ejector pin actuator, viewed in the direction of arrows 35--35 of FIG. 29. FIG. 36 is a front view of the gas connections for the gassing manifold. FIG. 37 is a sectional elevation viewed in the direction of arrows 37--37 of FIG. 36. FIG. 38 is a plan view of the sand magazine, viewed in the direction of arrows 38--38 of FIG. 1. FIG. 39 is a right side view in the direction of arrow 39 of FIG. 38. FIG. 40 is a front view, partly in section, of the sand magazine of FIG. 38. FIG. 41 is a front view, partly in section, of the blow plate clamping actuator mechanism, viewed in the direction of arrows 41--41 of FIG. 38. FIG. 42 is a sectional plan view in the direction of arrows 42--42 of FIG. 41. FIG. 43 is an enlarged front view of a blow plate clamp, viewed in the direction of arrows 43--43 of FIG. 38. FIG. 44 is a side view of the clamp of FIG. 43. FIG. 45 is a plan view of the blow body clamping assembly. FIG. 46 is a front view of the clamping assembly of FIG. 45. FIG. 47 is a schematic diagram of the control system. FIGS. 48-53 are simplified front views showing successive stages of the operating cycle of the apparatus. DETAILED DESCRIPTION OF THE INVENTION In the following description, the invention has been described as applied to the making of cores. However, as will be understood by those skilled in the art, the features of the invention are also applicable to the making of molds. Hence, reference to cores is for convenience and is not to be interpreted as limiting. Similarly, the terms "core boxes" and "mold boxes" may be used interchangeably herein. Referring to FIGS. 1-3 of the drawings, which show the overall arrangement of the principal components of the invention, the improved core-making machine of this invention comprises a mainframe 10 which includes four posts 12 interconnecting base plate 14 and horizontal upper beams 16. To one side of mainframe 10 there is mounted tool-loading and pick-off table 18, which comprises vertical legs 20 supporting horizontal rails 22 which in turn support and guide tooling 24. Tooling 24 comprises a series of stacked components including bottom stool 26, lower core box or drag 28, upper core box or cope 30, gassing manifold and ejector plate 32, blow plate 34 and sand magazine 36. Drag 28 and cope 30 contain cavities (not illustrated) for the core which is to be formed. These elements of the tooling are stacked on top of each other as a single unit when the tooling is initially installed on the tool-loading and pick-off table 18. Alternatively, gassing manifold and ejector plate 32, blow plate 34 and sand magazine 36 can be left in place within mainframe 10 following a previous operation, and not loaded along with the mold boxes and stool. Bottom stool 26 is provided with wheels 38 that permit the tooling to roll along rails 22 and onto pivotable rails 40 which are aligned with rails 22 and pivotally secured to mainframe 10. Rails 40 are adapted to pivot out of the path of vertically moving clamping table 42 by means of hydraulic rotary actuators 44. FIG. 1 illustrates tooling 24 in its initial position on tool-loading and pick-up table 18, and also shows in phantom the tooling in position on rails 40 of mainframe 10 after it has been automatically moved into such position by the mechanism to be described below. Also illustrated in FIGS. 1 and 3 is the telescoping table clamp cylinder 46 which functions to raise and lower tool clamping table 42. The lower end of cylinder 46 is fixed to base 14, while the extendable outer cylinder sleeve is secured to the underside of table 42. Adjacent to table lifting cylinder 46 there is mounted a series of lower ejector pin actuators 48 which are actuated by ejector cylinders 50 to eject the core from lower core box 28 following formation and curing of the core. Still referring to FIGS. 1 and 2, sand is loaded into the system by means of sand hopper 52 which interconnects with blow plate 34 and sand magazine 36 by means of blow sleeve 54. The flow of sand, which generally includes a binder, is controlled by a butterfly valve (not illustrated) and hopper valve actuator 56, while air is permitted to escape during the sand charging operation by means of sand magazine exhaust vent valves 58 and exhaust valve 60. Blowing air is supplied from pressurized air tank 62 under the control of blow valve control 64. FIGS. 1 and 3 also illustrate a mechanism for transferring the gassing manifold and ejector plate 32 between its operating and stand-by positions. A support frame 66 mounted on mainframe 10 carries a pair of hydraulic cylinders 68 which are connected to a transfer carriage 70 from which depend hanger brackets 72 and 73 which engage retainer brackets 74 on gassing manifold and ejector plate 32. Further details of the construction and operation of this transfer mechanism will be discussed below. FIGS. 2 and 3 also illustrate a series of cope hangers 76 which are pivotally mounted on frame crossmember 174 under the control of hydraulic cylinders 176 and which function to support the upper core box or cope during certain phases of the machine cycle. FIGS. 1 and 2 also illustrate a trolley and carriage mechanism which functions both to transfer tooling 24 into and out of the work station of mainframe 10 and also to pick off and remove the completed core from the tooling. Trolley 78 has wheels 80 which ride along tracks 22. Trolley 78 engages a horizontally movable carriage 82 for movement therewith by means of latch 84 and latch pin 86. Carriage 82 is supported for horizontal movement by means of guide supports 88, while movement of the carriage and trolley is controlled by a hydraulic transfer cylinder 90 operating through cable 92 and its connection 94 to the carriage. The plan view of FIG. 4, which shows tooling 24 in phantom (in both of its positions) and omits trolley 78 for clarity, shows gripper jaws 96 which form a portion of carriage 82 and which are adapted to releasably engage and grip coupling 98 which forms a portion of bottom stool 26 of tooling 24. The actuation means for jaws 96 will be further described below. FIGS. 1 and 2 also illustrate pick-off unit 100 which is pivotally mounted on trolley 78 under the control of hydraulic rotary actuator 102. As will be further explained below, pick-off unit 100 may be pivoted from its illustrated retracted position to an extended condition wherein it removes a completed and ejected core from the core boxes and transports the core out of the work station within mainframe 10. FIGS. 5 and 6 show further details of trolley 78 and pick-off unit 100. In the fragmentary plan view of FIG. 5, the fingers of the pick-off unit have been omitted for clarity. The fingers are adapted to be secured to mounting plates 104, which are in turn secured to bracket 106 which is clamped to pick-off finger pivot shaft 108. Pivot shaft 108 is selectively rotatable through approximately 180 degrees under the control of rotary actuator 102. As shown in the fragmentary front elevational view of FIG. 6, trolley 78 is provided with downwardly extending hold-down brackets 110, on the lower end of which are secured rollers 112 which engage the lower face of rails 22. These rollers stabilize the trolley and prevent it from tipping, particularly when the pick-off fingers are supporting a completed core. FIG. 7 shows additional details of the carriage and trolley. Previously mentioned carriage guide supports 88 support longitudinally extending carriage guide rods 114. Carriage 82 is provided with bushings 116 which engage and slidably grip guide rods 114. In this manner, carriage 82 is supported and guided during its longitudinal movement toward and away from mainframe 10. FIG. 7 also illustrates hydraulic cylinder 118 which controls the opening and closing of gripper jaws 96 on carriage 82. As shown on the left side of FIG. 7, and in contrast to the configuration of the corresponding elements on the righthand side of the figure, rail 22a and trolley wheel 80a have cooperating V-shaped profiles to maintain the trolley in its desired lateral position as it moves along the rails. FIG. 8 shows in greater detail portions of the pick-off unit 100 of FIGS. 5-7. Specifically, FIG. 8 illustrates the pick-off finger mounting arrangement and stops 120 and 122 which limit the pivotal movement in the withdrawn and extended positions, respectively. FIG. 9 illustrates a position-sensing mechanism whereby, when trolley 78 and carriage 82 are in their fully withdrawn or stand-by position, contact plate 124 on the carriage trips actuator 126 of limit switch 128 to indicate such condition to the control mechanism. FIGS. 10-13 illustrate details of the gripper jaw assembly by which carriage 82 engages and grips tooling 24 for longitudinal movement toward or away from mainframe 10. Gripper jaws 96 are pivotally mounted between upper and lower plates 130, 132, respectively, on pivot pins 134. The two jaw elements are biased toward each other by tension spring 136. Actuation of hydraulic cylinder 118, which is mounted on one of the jaws, extends cylinder rod 138 into engagement with the opposite jaw member, forcing the jaws apart to their released position, as illustrated in FIG. 12. In such released condition, contact pin 140 on one of the jaw elements engages actuator arm 142 of limit switch 144, thereby indicating that jaws 96 have disengaged from tooling coupling member 98. FIG. 14 illustrates additional details of the drive mechanism for trolley 78 and carriage 82. As previously explained, transfer cylinder 90 is secured to the tool-loading and pick-off table 18. The transfer cable is looped around a pair of pulleys 146, 148. Cable 92 is fixed to the piston (unillustrated) of transfer cylinder 90, this connection being internal of the cylinder. Thus, actuation of the cylinder causes the cable to move linearly about pulleys 146, 148, carrying with it carriage connector 94 and connector bracket 150. Bracket 150 has a pair of shock absorbers 152, 154 secured to it, these in turn being provided with spring-loaded plungers 156, 158, respectively. These shock absorbers function to cushion the end of the stroke of carriage 82 as it engages adjustable stops 160 or 162 at the respective limits of carriage travel. Cable tensioner 163 is an adjustable biasing means to apply continuous leftward force on pulley 146 to keep cable 92 free of slack. FIG. 15 is an enlarged fragmentary view showing details of the clamping table 42 and clamping cylinder 46. As previously stated, clamping cylinder 46 is of telescoping construction, including an extendable hollow cylinder rod 164 which telescopes over fixes inner cylinder rod 166 which, in turn, is secured to mainframe base 14 by nut 168. Outer cylinder sleeve 169, in turn, telescopes over rod 164 so that the potential stroke of cylinder 46 is almost twice the stroke of a conventional cylinder. The telescoping construction of cylinder 46 permits a more compact assembly, without the need for a pit beneath the floor to accommodate the required stroke of a conventional cylinder. A suitable telescoping cylinder for this purpose is manufactured by Precision Hydraulics & Engineering, Inc., of Signal Hill, Calif. The vertical position of lower ejector pin actuators 48 is sensed by upper and lower limit switches 170, 172, respectively, which are tripped by flanges on lower ejector pin actuators 48. Ejector pin actuators hang or are spring-biased to their downward position illustrated in FIGS. 15 and 16, but they are adapted to be displaced upwardly when cylinders 50 are extended. As will be understood by those skilled in the art, bottom stool 26 is provided with a conventional ejector plate mechanism (not illustrated) adapted to be engaged and actuated by ejector pin actuators 48 so that ejector pins 390 (see FIG. 53) may enter aligned holes in drag 28 to eject the completed core from the drag cavity. The upper portion of FIG. 15 shows a mainframe crossmember 174 on which cope hangers 76 are mounted for pivotal movement under the influence of hydraulic cylinders 176. Cylinders 176 cause hangers 76 to swing from a stand-by position, which provides clearance for vertical passage of tooling 24, and an extended position in which they support the upper core box or cope. A pair of limit switches 178 sense the two pivotal positions of cope hanger 76. FIG. 16 illustrates additional details of the clamping table and related structure. Guidance and stabilization of clamping table 42 throughout its vertical movement is provided by guide rod bushings 180 which are secured to frame crossmember 182. These bushings receive guide rods 184 which are secured to the underside of clamping table 42. Also shown in FIG. 16 are two of the four clamping units 186 which are pivotally secured to brackets 188 and caused to pivot by shafts 190. As will be further explained below, clamping units 186 function to clamp tooling 24 to clamping table 42. Referring now to FIGS. 17 and 18, there is illustrated the mechanism for causing pivotal rails 40 to swing out of the path of the tooling. The rails are mounted for pivotal movement with pivot shafts 192. Hydraulic rotary actuators 44 cause rotational movement of shafts 192 by means of a rack and pinion arrangement which is not illustrated but which may be similar to that illustrated in FIG. 41. Brackets 194 are similarly clamped to pivot shafts 192 so that actuation causes simultaneous pivotal movement of brackets 194, shaft 192 and rails 40. Contact screws 196 are mounted on brackets 194 for engagement with rail position-indicating limit switches 198 and 200. FIGS. 19-22 show the clamping mechanism for clamping tooling 24 to table 42. As shown in FIGS. 19-20 cylinders 202 have shaft extensions 190 which simultaneously stroke outwardly upon actuation of the cylinder. Each shaft has a camming slot 204 which is skewed relative to the shaft axis, as seen in FIG. 21. Follower pin 206 in clamp 186 rides in slot 204, whereby longitudinal stroking of shaft 190 by cylinder 202 causes the sides of slot 204 to cam follower pin 206 so as to pivot clamp 186 into or out of its clamping position. In the solid line clamping position shown in FIG. 22, clamp 186 engages a flange on bottom stool 26 to retain tooling 24 in position on table 42. Shaft extensions 190 carry actuators 208 which trip limit switches 210 to indicate the condition of clamps 186. FIG. 23 is a sectional view of the previously described structure beneath clamping table 42, showing table clamp cylinder 46, guide rods 184, lower ejector pin actuators 48 and a representative lower limit switch 172. FIG. 24 illustrates the mechanism for sensing the vertical elevation of clamping table 42. A pair of vertical rods 214 extend downwardly from the underside of the table, each rod having an enlarged cam portion 216 adapted to trip limit switches 218 to thereby indicate when the table has reached a predetermined position. FIGS. 25-28 illustrate, in further detail, the cope hanger construction previously described in relation to FIG. 15. Cope 30 is shown in phantom in the plan view of FIG. 25 and in the fragmentary cross-sectional elevation of FIG. 27. Each of cope hangers 76 is mounted for pivotal movement with a pivot shaft 220 which is rotatably received within bracket 222 secured to frame crossmember 174. Cylinder rod 224 of cope hanger actuating cylinder 176 is connected to an actuating lever 226 which is secured to pivot shaft 220 for rotation therewith. Thus, linear movement of cylinder rod 224 causes pivotal movement of lever 226, shaft 220 and cope hanger 76. Brackets 228 provide support for the opposite end of each of hydraulic cylinders 176. As best shown in FIG. 27, each of cope hangers 76 has an upwardly tapering cope locating pin 230 which is adapted to seat in a downwardly opening socket 232 at each of the four corners of cope 30. In this manner, cope hangers 76 function to both locate and support cope 30 during the appropriate portion of the cycle. A limit switch actuator 234 on each of cylinder rods 224 functions to trip the appropriate limit switch 178 to indicate the condition and position of cope hangers 76. FIGS. 29 and 30 show further details of the gassing manifold and ejector plate transfer mechanism generally shown in FIG. 1. As previously explained, a gassing manifold transfer support frame 66 is secured to one end of mainframe 10. Hydraulic cylinder 68, which functions to traverse gassing manifold transfer carriage 70 between its active and stand-by positions, has a cylinder rod 236 which is secured to a bracket 238 on carriage 70. In FIG. 30, carriage 70 is shown in its operative position at the left side of the figure, whereas the stand-by position is shown in phantom at the right side of the figure. Carriage 70 is supported during its traverse by means of guide rods 240, which are mounted on mainframe 10 and gassing manifold transfer support frame 66, and by guide rod bushings 242 on carriage 70 (see FIG. 31 for further illustration of the guide rods and bushings). As shown in FIG. 29, a pair of shock absorbers 244 is mounted on frame 66 to cushion the end of the stroke of gassing manifold transfer carriage 70 as it reaches the end of its stroke toward its stand-by position. Similarly, another pair of shock absorbers 246 is mounted on carriage 70 itself (see FIGS. 29 and 35). When the carriage reaches the end of its stroke toward its operative position, the spring-loaded plungers of shock absorbers 246 engage stop members 248 which are carried by brackets 250 mounted on mainframe member 252. As best shown in FIGS. 29 and 31, limit switches provide a signal when carriage 70 has reached its respective positions. Specifically, an actuator 254 on carriage 70 trips limit switch 256 on support frame 66 when the carriage reaches its stand-by position, whereas limit switch 258 on mainframe member 252 is positioned to be tripped by actuator 260 on carriage 70 when the carriage reaches its operative position. FIGS. 30 and 31 further show two pairs of gassing manifold hanger brackets 72, 73 which are mounted on carriage 70 and which engage retainer brackets 74 on gassing manifold and ejector plate 32, as will be further described below. FIGS. 32 and 33 illustrate the actuating mechanism for the upper ejector pins. A pair of hydraulic cylinders 262 is secured to a portion of mainframe 10. Output rods 264 of the cylinders extend downwardly into selective engagement with the first of the series of interengaging rocker arms 266, each of which is pivotally mounted on a bracket 268 secured to top plate 270 of gassing manifold and ejector plate 32. As best shown in FIG. 33, downward extension of cylinder rod 264 brings it into engagement with the righthand rocker arm 266, causing such rocker arm to pivot clockwise and to force the righthand pushrod 272 downward through an opening in top plate 270 and into engagement with ejector pin plate 274. This rocking movement of righthand rocker arm 266 causes similar rocking action by each of the other interengaged rocker arms, forcing the other pushrods downward into engagement with ejector pin plate 274. Plate 274 is normally biased upwardly by compression springs 276 held between plate 274 and gassing manifold bottom plate 278. A plurality of ejector pins 280 extend downwardly from their connection to ejector pin plate 274 and through aligned openings provided in upper core box or cope 30 located immediately beneath gassing manifold 32. A plurality of parting line pins (not illustrated) are secured to the underside of ejector pin plate 274 and extend downwardly into engagement with the top of drag 28 when the mold boxes are closed and in raised position against gassing manifold bottom plate 278. These parting line pins prevent downward deflection of ejector pin plate 274 until the mold boxes have separated from each other, thereby preventing damaging premature pressure of ejector pins 280 on the newly-formed core within the mold cavity. Top and bottom plates 270, 278, respectively, define a manifold chamber 281. The access openings for pushrods 272 are provided with guide bushings and suitable sealing means to substantially prevent gas leakage therethrough. FIG. 32 also illustrates one of a pair of gas pipe connections 282 which supply catalyzing gas to the interior of gassing manifold 32, as will be further discussed below. FIG. 34 shows an enlarged detail of gassing manifold hanger bracket 72. Bracket 72 has a cut-out portion 284 which is adapted to receive a portion retainer bracket 74 on gassing manifold and ejector plate 32. When these elements have engaged, hydraulic cylinder 286 is actuated to extend cylinder rod 288 to clamp gassing manifold retainer bracket 74 within hanger bracket 72. Similarly, retraction of cylinder rod 288 permits separation of gassing manifold and ejector plate 32 from hanger bracket 72. FIG. 35, a portion of which has previously been described, shows the manner in which upper ejector pin hydraulic cylinder 262 is secured to mainframe member 252. FIGS. 36 and 37, in addition to showing the previously described hydraulic cylinder 262 which actuates the upper ejector pins, further show the connections for supplying catalyzing gas to gassing manifold and ejector plate 32. As also illustrated in FIG. 32, gas pipe connection 282 is fixed to top plate 270 of the gassing manifold and ejector plate 32. At the proper point in the operating cycle, the upper opening of connection 282 is moved upwardly into abutting and sealed connection with a fixed gas supply pipe 290 which is secured to mainframe crossmember 252. As shown in FIG. 37, an O-ring 286 is provided to seal this abutting connection. The upper end of supply pipe 290 is connected to a source of catalyzing gas (unillustrated). At the proper time in the operating cycle, gas is caused to flow through pipe 290 and connection 282 into gassing manifold chamber 281 (see FIG. 33) and from such chamber through the clearance gaps surrounding ejector pins 280 in bottom plate 278 and into aligned channels in cope 30 leading to the formed part within the mold box cavity. FIG. 38 shows additional details of sand magazine 36 and the clamping mechanism by which blow plate 34 is clamped to the lower side of the sand magazine. Additional details of the clamping mechanism are shown in FIGS. 41-44, which should be referred to in connection with the following description. The blow plate clamping mechanism includes a pair of clamping cylinders 294 which are secured to main frame 10 by means of bracket 296. Each of cylinders 294 has a cylinder rod 298 which abuts the end of a cooperating rack gear 300. Both rack gears engage a pinion gear 302 which rotates in conjunction with adjacent pinion gear 304 on the same shaft. Gear 304 in turn meshes with spur gear 306 which is keyed to shaft 308. Rack gears 300, pinion gears 302 and 304, spur gear 306 and shaft 308 are all mounted within gear housing 310 secured to sand magazine 36. At each of end of shaft 308 there is a bevel gear set 312 which provides driving engagement with similar bevel gears on three additional clamping shafts 314. Thus, shaft 308 and the three additional shafts 314 are arrayed around four sides of sand magazine 36 and are rotatably mounted in brackets 316 secured to the sand magazine. FIGS. 43 and 44 illustrate the manner in which a typical clamping unit 318 clamps blow plate 34 to sand magazine 36. Each clamping unit comprises a clamping arm 320 and an actuating arm 322, each keyed to shaft 308. A lateral projection 324 on arm 322 overlaps arm 320, and a compression spring 326 retained between these overlapping portions continuously biases the arms away from each other. While actuating arm 322 is keyed to shaft 308 for direct pivotal movement therewith, it can be seen in FIG. 43 that key 328 for clamping arm 320 is placed in an oversized slot 330 in arm 320. This arrangement permits a limited amount of lost motion between the rotation of shaft 310 and the pivoting movement of clamping arm 320. Such lost motion feature avoids overstressing of the clamping and clamped elements and eliminates the need for close control of tolerances on all of the clamping members around the four sides of the blow plate, as would otherwise be necessary to assure simultaneous and even clamping pressure at all clamping locations. Thus, once blow plate 34 is securely clamped against sand magazine 36 at a particular clamping unit, further rotation of shaft 310 and actuating arm 322 is still possible, without accompanying rotation of clamping arm 320. Nevertheless, firm clamping pressure will continue to be exerted because of compression spring 326. FIGS. 38 and 41 also illustrate a limit switch arrangement which signals the condition of the blow plate clamping system. Each of hydraulic cylinders 294 has a cylinder rod extension 332 provided with a pair of limit switch actuators 334 which engage one or the other of a pair of limit switches 336. Thus, these limit switches generate a signal which indicates whether the clamping mechanism is in either its clamped or released condition. FIGS. 38 and 40 also illustrate a pair of guide brackets 338 secured to the corners of sand magazine 36. These brackets are provided with guide holes 340 through which cylinder rods 264 of the upper ejector pin actuating mechanism project (see also FIGS. 35-36). FIG. 39 also shows a handle and locking device 342 for a sand magazine clean-out door. Also shown is a pneumatic line 344 fixed to mainframe 10 and adapted to connect with connector line 346 on sand magazine 36 at coupling joint 348 when brought into abutting engagement upon upward movement of the sand magazine. This pressurized air is used to actuate exhaust vent valves 58 between their open position during sand charging and their closed position during blowing. FIGS. 45 and 46 illustrate blow body clamping assembly 350 which forms a part of blow sleeve 54 and which removably clamps blow sleeve 352 to sand magazine flange 354. Assembly 350 includes annular blow body 356 from which extend four brackets 358 which in turn support reversible hydraulic drive motor 360 and rotatably mounted threaded drive shaft 362. Rotation of drive shaft 362 causes simultaneous rotation of driven shaft 364 by means of sprockets 366, 368 and connecting drive chain 370. Shafts 362 and 364 are each provided with oppositely threaded segments so that shaft rotation causes the two opposed C-clamp rings 376, 378 to move toward or away from each other, depending upon the direction of rotation. Actuator 380 on C-clamp ring 376 is positioned to trip limit switches 382, 384 to thereby generate signals responsive to the clamped or released condition of clamping assembly 350. Air inlet 386 provides a connection point for blowing air from supply tank 62 and blow control valve 64 (see FIG. 2). FIG. 47 is a simplified schematic block diagram showing a control system for operating the foundry machine of the present invention. It is contemplated that the operating cycle would be controlled by a suitable programmable controller, such as manufactured by Allen-Bradley of Milwaukee, Wis. SEQUENCE OF OPERATION In connection with the description of the operation of the foundry machine throughout its cycle, reference should first be made to FIG. 1, and then to the simplified views of FIGS. 48-53. FIG. 1 shows all of the tooling 24 initially on tool loading table 18. The tooling includes sand magazine 36, blow plate 34, gassing manifold and ejector plate 32, cope 30, drag 28 and bottom stool 26. These elements are merely stacked on each other by appropriate nesting or other formations. They are not clamped together. The arms of core pick-off unit 100 are in their illustrated retracted position. Pivotable rails 40 on mainframe 10 are in their normal vertically oriented operative position, as illustrated in FIG. 17. Transfer cylinder 90 is then actuated to bring gripper jaws 96 of carriage 82 into engagement with tooling coupling 98 on bottom stool 26. Next, hydraulic cylinder 118 is actuated to clamp jaws 96 onto coupling 98, and the tooling may then be transferred from tool loading and pick-off table 18 onto the aligned pivotable rails 40 of mainframe 10 (see FIGS. 4-6 and 10-14). That is the condition of the apparatus shown in solid lines in FIG. 48. Next, gripper jaws 96 are released from tooling coupling 98 so that trolley 78 and carriage 82 may be returned to their stand-by position illustrated in phantom in FIG. 48. Table clamp cylinder 46 is then actuated to lift tooling 24 off of pivotable rails 40 and to bring tooling 24 up into engagement with blow sleeve 54. With the tooling lifted off rails 40, rotary actuator 44 is actuated to swing rails 40 outwardly to provide clearance for the table to be subsequently lowered below its starting position (see FIGS. 15-18). As clamping table 42 moves upwardly, hydraulic cylinders 202 are actuated to clamp bottom stool 26 to the table by means of clamping units 186 (see FIGS. 19-22). During this part of the cycle, cope hangers 76 are in their withdrawn position (shown in phantom in FIG. 25), to provide clearance for the vertically moving tooling. Sand magazine 36 is the clamped to blow sleeve 54 by clamping assembly 350 (see FIGS. 45-46), and blow plate 34 is clamped to sand magazine 36 by clamping units 318 (see FIGS. 38-44). As the next step in the cycle, gassing manifold transfer carriage 70 is brought from its stand-by position shown in FIG. 48 to its clamping position shown in FIG. 49 by means of hydraulic cylinder 68. Hydraulic cylinder 286 is actuated to clamp hanger bracket 72 to retainer bracket 74 on gassing manifold 32 (see FIGS. 29 to 34). Next, cope hangers 76 are swung into their operative position by means of hydraulic cylinders 176 (see FIGS. 25-28). Next, clamping table 42 is lowered to permit carriage 70 to move gassing manifold and top ejector plate 32 to its stand-by position. As tooling 24 moves downwardly, upper core box or cope 30 is deposited onto cope hangers 76 so that it is supported thereby. Bottom stool 26 and lower core box or drag 28 continue to move downwardly with clamping table 42, thus establishing the separation from cope 30 as shown in FIG. 50. In the condition of FIG. 50, the machine is exactly as it would be if a completed part had been removed, and the machine is ready to start a repeat cycle to form another part. Hence, from this point on, the description of the sequence is the same for either a repetitive part-forming cycle or the formation of the first part with a newly-loaded complete set of tooling 24. With the gassing manifold and ejector plate 32 out of the way, table 42 is once again raised, bringing drag 28 up into contact with cope 30 which is suspended on cope hangers 76. Continued upward movement of the table and tooling lifts cope 30 off of its hangers 76 and carries it upward until it engages blow plate 34. This is the condition of the apparatus illustrated in FIG. 51. Next, sand and binder are introduced into hopper 52 and a butterfly valve (not illustrated) is opened by valve actuator 56 to admit this charge into sand magazine 36 (see FIG. 2). The butterfly valve is then closed and the sand magazine is pressurized with air from tank 62. This pressurization forces the sand from the magazine through blow plate 34 and into the core-defining cavity within the core boxes, thereby forming the core. After the core is initially formed, table 42 is lowered a sufficient distance to permit carriage 70 to transfer gassing manifold and ejector plate 32 into position beneath blow plate 34. Table 42 is once again raised to engage the underside of the gassing manifold and ejector plate. This upward movement brings gas pipe connection 282 on the gassing manifold into sealing contact with fixed gas supply pipe 284 (see FIGS. 36-37). This is the condition illustrated in FIG. 52. Catalyzing gas is then introduced through these connections into the gassing manifold and ejector plate 32 and into the core boxes, catalyzing and hardening the newly-formed core. Purging air is then applied to the mold box cavity through the same path as the gas to remove excess gas. During or immediately following the gassing step, cope hangers 76 are sung back into their operative position. Table 42 is lowered, and simultaneously top ejector pins 280 are actuated by hydraulic cylinder 262 (see FIG. 33) and lower ejector cylinders 50 are actuated. As table 42 starts downwardly, cope 30 engages cope hangers 76 and becomes supported thereby while table 42 and drag 28 continue down. As the two mold boxes separate, the top ejector plate is no longer constrained by the parting line pins and can move downwardly under the pressure from cylinder 262. Top ejector pins force core 388 out of the cope cavity. Meanwhile, lower ejector pin actuators 48 descent into contact with the upwardly extended rods of lower ejector cylinders 50, camming actuators 48 up into engagement with the lower ejector pin mechanism within bottom stool 26, thereby extending lower ejector pins 390 therefrom, and ejecting core 388 from drag 28. The fingers of pick-off unit 100 are then swung to their active position by rotary actuator 102 (see FIG. 6). Referring next to FIG. 53, core 388 is shown supported on lower ejector pins 390, with sufficient gap above drag 28 to permit the fingers of pick-off unit 100 to enter. Carriage transfer cylinder 90 is actuated to cause carriage 82 and trolley 78 to traverse toward the right as viewed in FIG. 53 so that the pick-off fingers 100 are properly positioned beneath core 388. Lower ejector cylinders 50 are then retracted so that core 388 is gently placed onto and supported by the pick-off unit fingers. Trolley 78 is then retracted toward its stand-by position shown in FIG. 53, from which the core can be removed either manually or by robotic equipment. It should be noted that FIG. 53 shows gassing manifold and ejector plate 32 in its retracted position. The withdrawal of that unit by carriage 70 can occur as soon as part 388 has been ejected from the molds. However, it may be preferable to defer such withdrawal until after part 388 has been removed by fingers 100, because gas vapors which may be harmful to the blow fan may be still be given off by part 388 after its ejection. The gassing manifold and ejector plate 32, if temporarily left in place on cope 30, can shield such vulnerable parts from these vapors. If another part is to be formed using the same tooling, table 46 is then raised to carry stool 26, drag 28 and cope 30 up into engagement with blow plate 34, whereupon the cycle can be reapeated. Alternatively, if the tooling is to be removed, gassing manifold and ejector plate 32 is returned to its position beneath blow plate 34 (if it was not previously left in such position), and work table 42 is raised to carry stool 26, drag 28, cope 30 and gassing manifold and ejector plate 32 up into engagement with blow plate 34, with empty carriage 70 first being withdrawn to its stand-by position when cope 30 is raised far enough to engage and support gassing manifold and ejector plate 32. Clamps 318 and 350 (see FIGS. 45-46) are then released to disengage sand magazine 36 from blow plate 34 and from blow body 54. While work table 42 is in its raised position, pivotable rails 40 are swung back into their operative position. Table 42, with all of the tooling 24 stacked thereon, may then be lowered to bring wheels 38 of stool 26 to rest on tracks 40, whereupon carriage 82 is actuated toward the right by cylinder 90 so that gripper jaws 96 can engage tooling coupling 98 on tooling 24. Then, carriage 82 is returned to its standy-by position, bringing the tooling 24 onto tool-loading and pick-off table 18. The invention may be further developed within the scope of the following claims. Accordingly, the foregoing specification is to be interpreted as illustrative of a single operative embodiment, rather than in a strictly limited sense.
A foundry machine for forming molds or cores from a molding material such as sand provides completely automated loading and unloading of tooling elements (24). The tool elements (24) comprising a sand magazine (36), blow plate (34), combined gassing manifold and top ejector unit (32), upper mold box (30), lower mold box (28) and bottom stool (26) are automatically transferred, in stacked, separable relationship, by tracks (40) to a vertically displaceable, work table. Vertical displacement of the work table (42) sequentially elevates the tooling elements (24) to positions within a mainframe (10) where automatically operated clamping means secure the appropriate tooling elements (24) in respective operating positions. The gassing manifold (32) includes an ejector pin assembly (274, 280) mounted therewithin.
1
This invention is made with government support under Grant No. CHE 910 4112 awarded by the National Science Foundation. The government has certain rights in the invention. FIELD OF THE INVENTION The present invention relates to a method for the preparation of silyl-terminated polyolefins. More particularly, the invention relates to a method for synthesizing polyolefins having a silyl group at one terminus, said method comprising polymerizing α-olefins in the presence of a metallocene catalyst using a silane as a chain transfer agent. BACKGROUND OF THE INVENTION Catalyst systems for the polymerization of olefins are well known in the art. Typically, these systems include a Ziegler-Natta type polymerization catalyst; a co-catalyst, usually an organoaluminum compound; an electron donor compound (optional), and an olefin monomer. Control of molecular weight is important as it influences the final physical properties of the polymer. The molecular weight is controlled by chain transfer reactions which terminate the growth of the polymer chains. A number of such chain transfer processes, including β-H elimination, β-alkyl elimination and chain transfer to MR n (M═Zn, Al, etc.), monomer, and hydrogen have been identified. Of these, hydrogen has been found to be the most practical chain transfer agent since it is generally easy to use and normally does not affect the activity of the catalyst. However, there are many cases where even hydrogen does not provide the optimum results due to some undesired side effects (e.g., unresponsive M--R bonds, overactivation of the catalyst, too rapid hydrogenation of other functional groups). Therefore, alternative chain transfer agents for use in the production of polyolefin homopolymers and copolymers, are highly desirable. Terminally functionalized polymers are of great current interest. Such a polymer could be used as precursor for making block or graft polymers and would be expected to exhibit modified chemical and physical properties. It has previously been disclosed in U.S. Pat. No. 5,578,690 that certain silanes can be used as chain transfer agents when ethylene, or a combination of ethylene and an α-olefin, is polymerized with certain metallocene catalysts. There the method resulted in an ethylene polymer, or co-polymer of ethylene and an α-olefin, having a silyl group at one terminus of its chain. Unfortunately, this organolanthanide polymerization system is limited to ethylene polymerization and copolymerization and cannot be expanded to homopolymers of higher α-olefins. SUMMARY OF THE INVENTION Accordingly, it is an object of the subject invention to prepare and utilize a new class of olefin polymerization catalysts. A further object of the subject invention is a catalyst which permits better control over molecular weight and molecular weight distribution of such polymers of higher α-olefins. Another object of the subject invention is a Ziegler-Natta type catalyst system which reduces the use of excess co-catalyst. These and other objects are attained in the subject invention whereby in one embodiment there is a method to produce silyl-capped polyolefins and the silyl-capped polyolefins thereby prepared. This method includes polymerization of α-olefins with silanes as chain transfer reagents using group 4 Ziegler-Natta homogeneous catalysts. The method involves reacting α-olefins (C≧3), catalyzed by group 4 metal catalysts in hydrocarbon solvents in the presence of a silane having the formula R(SiR 2 R 3 R 4 ) n , wherein R is H, a hydrocarbon (1≦C≦10) or silyl group each having a valence equal to or and, at least, one of R 2 , R 3 and R 4 is H and the other of R 2 , R 3 and R 4 may be a monovalent group independently selected from the group consisting of: hydrogen, alkyl radicals, aryl radicals, alkylaryl radicals, arylalkyl radicals, alkoxy radicals (1≦C≦20); phenoxy radical, fluorinated alkyl radicals (3≦C≦6), dialkylamino group in which the alkyl groups contain 1 to 4 carbon atoms, a diorganopolysiloxane chain containing 1 to 10 siloxane units and n=1-6 and when R is H, n is 1. DETAILED DESCRIPTION OF THE INVENTION The primary component of the present invention is selected from an α-olefin (C≧3) or a combination of two or more such α-olefins. Specific examples of suitable α-olefins include styrene, propene, 1-butene, 1-pentene, 1-hexene, and 1-octene. Another component of the instant method is a silane having the formula R.paren open-st.SiR.sup.2 R.sup.3 R.sup.4).sub.n (i) wherein R is H, a hydrocarbon, or silyl group each having a valence equal to n and at least one of R 2 , R 3 , and R 4 is H, and the other of R 2 , R 3 and R 4 is a monovalent group independently selected from the group consisting of: hydrogen, alkyl radicals, aryl radicals, alkylaryl radicals, arylalkyl radicals, alkoxy radicals (1≦C≦20); phenoxy radical, fluorinated alkyl radicals (3≦C≦6), dialkylamino group in which the alkyl groups contain 1 to 4 carbon atoms, a diorganopolysiloxane chain containing 1 to 10 siloxane units and n=1-6 and when R is H, n is 1. More specifically, R, R 2 , R 3 and R 4 each may represent a monovalent group independently selected from hydrogen, halogen, alkyl radicals having 1 to 20 carbon atoms, aryl radicals such as phenyl and tolyl, alkylaryl radicals such as ethylphenyl and ethyltolyl, arylalkyl radicals such as phenylethyl and benzyl, alkoxy or amide radicals having 1 to 20 carbon atoms, phenoxy radicals, fluorinated alkyl radicals having 3 to 6 carbon atoms such as 3,3,3-trifluoropropyl, a dialkylamino group in which the alkyl groups contain 1 to 20 carbon atoms and a diorganopolysiloxane chain containing 1 to about 10 siloxane units in which the organic groups are independently selected from alkyl radicals having 1 to 6 carbon atoms, aryl radicals, fluorinated alkyl radicals, silyl groups or alkoxy radicals having 1 to 4 carbon atoms. Preferred groups which are bonded to the silicon atom of the above formula (i) include hydrogen, methyl, ethyl, isopropyl, isobutyl, phenyl, methoxy, ethoxy, chlorine, 3,3,3-trifluoropropyl, dimethylamino and siloxane groups of the formula R'.sub.3 SiO(SiR'.sub.2 O).sub.j -- (ii) in which R' is independently selected from methyl, phenyl, 3,3,3-trifluoropropyl, methoxy or ethoxy groups and j has a value of 0 to 10. Highly preferred silanes, according to the instant method, are phenylsilane, diphenylsilane, phenylmethylsilane, pentamethyldisiloxane, methylsilane, and dimethylsilane. The catalyst is selected from a metallocene catalyst or a metallocene catalyst in combination with a co-catalyst. The metallocene catalyst of the invention has a general composition of Cp m MX n Y p or C p MX d and a co-catalyst, where the catalyst is typically a constrained geometry catalyst: ##STR1## wherein Cp denotes a cyclopentadienyl, a substituted cyclopentadienyl radical, or a fused cyclopentadienyl radical, such as an indenyl radical. Examples of substituted Cp groups include C 5 R* 4 , in which R* is selected from the group consisting of hydrogen, alkyl having 1 to 20 carbon atoms, aryl having 6 to 18 carbon atoms and triorganosilyl, such as trimethylsilyl. A specific Cp group includes tetramethylcyclopentadienyl (Cp'=η 5 -C 5 Me 4 ), wherein Me hereinafter denotes a methyl radical and η 5 indicates pentahapto coordination to the metal. Further: M is a metal of group 3, 4, 5, 6, 7, 8, 9, 10 or an element of the actinide or lanthanide groups, and preferably Ti, Zr or Hf; X is an inert anionic ligand (C≦20); Y is a heteroatom ligand, such as --O--, --S--, --NR*--, --PR*-- or a neutral two electron donor ligand such as --CR*, --SR*, --NR* 2 , and --PR* 2 ; Z is SiR* 2 , CR* 2 , SiR 2 SiR * 2 SiR* 2 , CR* 2 CR* 2 , CR*═CR*, CR* 2 SiR* 2 , GeR* 2 , SnR 2 *, wherein: R*, each occurrence, is independently selected from the group consisting of hydrogen, alkyl, aryl, silyl, halogenated alkyl, halogenated aryl groups having up to 20 carbon or non-hydrogen atoms, and mixtures thereof, or two or more R* groups from Y, Z or both Y and Z form a fused ring system. m, n and p are independent; p is 0, 1 or 2; m is 0, 1, 2 or 3; n is 1, 2, 3 or 4; the sum of m and n is equal to the valence of M; d is 1 or 2; The co-catalyst may be weakly acidic and can be any of the compatible, noncoordinating or weakly coordinated anions (preferably BR - 4 ), organo-Lewis acids, preferably BR* 3 , methylalumoxane (MAO) and AlX q R* 3-q , etc., wherein R* independently is alkyl or aryl or substituted aryl, X is a halogen, 0≦q≦3. It should be noted that whereas formula iii and the following formulas indicate a cyclic structure for the catalysts, when Y is a neutral two electron donor ligand, the bond between M and Y is more accurately referred to as a coordinate-covalent bond. Also, it should be noted that the complex may exist as a dimer or higher oligomer. Specific examples of the above metallocene catalysts include compounds having the following formulas, in which Me, Cp' and Cp" have their previously defined meanings: ______________________________________Me.sub.2 SiCp"(t-BuN)TiMe.sub.2 Cp'ZrMe.sub.3 rac-C.sub.2 H.sub.5 (Indenyl).sub.2 TiMe.sub.2 Me.sub.2 SiCp"(t-BuN)HfMe.sub.2 Cp'TiMe.sub.3 Cp' = η.sup.5 --C.sub.5 Me.sub.4 Me.sub.2 SiCp"(t-BuN)ZrMe.sub.2 Cp'HfMe.sub.3 Cp' = η.sup.5 --C.sub.5 Me.sub.5______________________________________ The above described catalysts are known in the art and they may be employed in particulate form, as a homogeneous solution or supported on inert materials such as alumina, methylalumoxane-activated silica, silica, silica-alumina and magnesium chloride, inter alia. They may be prepared by e.g., methods taught by Den Haan et al. in Organometallics, vol. 5, 1726-33, 1986; Mohring et al. in Journal of Organometallic Chemistry vol. 479, 1-29, 1994; U.S. Pat. Nos. 4,871,705 and 5,001,205 to Hoel; U.S. Pat. Nos. 4,801,666 and 4,668,773 to Marks and by Marks et al. in Journal of the American Chemical Society, vol. 107, 8091-8103, 1985. For the purposes of the present invention, a co-catalyst is also added when m=1, p=0, and n=3 and when M=Ti, Zr or Hf. This co-catalyst is used, for example, to activate the metallocene catalyst and may be selected from alkylalumoxanes, trialkyl boron compounds in which the alkyl radicals have 1 to 8 carbon atoms or triaryl boron compounds in which the aryl radicals have 6 to 8 carbon atoms or borate reagents such as R' 3 NH + BR - 4 or Ph 3 C + BR - 4 where R' is an alkyl, aryl group or perfluoroaryl group. A highly preferred co-catalyst is methylalumoxane (MAO). Certain co-catalysts, such as MAO, also act as oxygen scavengers and desiccants and are beneficial for these functions as well. Alternatively, the co-catalyst can be a compound having the formula AlG k R 6 .sub.(3-k) in which G is selected from hydrogen, halogen, alkyl radicals having 1-8 carbon atoms or aryl radicals having 6 to 8 carbon atoms, R 6 is an alkyl radical having 1-8 carbon atoms and k is an integer having a value of 0 to 3. Various metallocene catalysts which require a co-catalyst are described in above-cited U.S. Pat. Nos. 4,871,705 and 5,001,205 to Hoel, the disclosures of which are hereby incorporated by reference. Particularly, catalysts wherein X=halogen require a co-catalyst, MAO is preferably used in combination therewith. Based on the instant disclosure and the patent as well as scientific literature, those skilled in the art will readily identify circumstances wherein a co-catalyst is desirable by routine experimentation (e.g., based on rate of reaction, polymer yield and molecular weight). In a preferred embodiment of the instant method, the catalyst and silane are first mixed, preferably in a non-polar hydrocarbon solvent, such as toluene, butane, pentane, hexane, octane and iso-octane, for example. Preferably the solvent is toluene. Alternatively, the silane itself can act as a solvent if a low molecular weight polymer is desired. The above mixing operation must avoid the introduction of moisture or oxygen. The latter condition may be satisfied by running the reaction under an inert atmosphere, such as nitrogen or argon, as is standard in the art. The α-olefin (or a mixture of an α-olefin and another different α-olefin) is introduced while the ingredients are vigorously agitated and the polymerization reaction is carried out at a temperature of about -100° C. to +200° C., preferably -20° C. to +150° C. The pressure during polymerization is typically controlled at 1 to 100 atmospheres, preferably 1 to 5 atmospheres, and is determined by temperature in a closed system or by the pressure of the volatile components in a continuous polymerization. When a second α-olefin having a boiling point above the reaction conditions is used, it may be added simultaneously with the first α-olefin. When the silane is a gas under the reaction conditions, it may also be added simultaneously with the α-olefin in the desired ratio to produce the silyl-terminated polymer or co-polymer. Upon completion of the reaction, the silyl-terminated polymer sometimes precipitates out of solution when a solvent is used. The polymer can also be recovered by evaporating the solvent. If the reaction is to be carried out without the use of a solvent (e.g., in a gas phase reaction using a supported catalyst), the reaction temperature is preferably adjusted such that the silane and α-olefin are both gases. In this case, the mixture of α-olefin and silane is exposed to the catalyst and the polymer formed may be removed as a melt from the bottom of the reactor. The polymer or copolymer may be purified by re-precipitation or by some other conventional technique. The above polymerization reaction may be summarized by the following generalized equation: ##STR2## wherein where R is H, a hydrocarbon or silyl group, and M is a metal, as previously defined n represents the average degree of polymerization. Although the inventors of the instant method do not wish to be bound by a particular mechanism or theory, it is believed that, at least for the lanthanide catalysts and titanium constrained geometry catalysts of the invention, the chain transfer step involves the transfer of the polyolefin to the silicon moiety and the molecular weight of resulting polymer is controlled by the concentration of silane chain transfer reagent and the simultaneous regeneration of active catalyst, which readily participates in the next catalytic cycle. This is best shown in Table 1. TABLE I__________________________________________________________________________Propylene and 1-Hexene Polymerization; Ethylene 1-Hexene and Ethylene- Styrene Copolymerization in the Presence of [Me.sub.2 Si:(Me.sub.4C.sub.5)(t- BuN)]TiMe.sup.+ B(C.sub.6 F.sub.5).sub.4 .sup.- and PhSiH.sub.3 monomer comonomer PhSiH.sub.3 Polymer comonomer Entry Time/Temp. (1 atm) (M) (M) yield incorp(M %) M .sub.n .sup.b M.sub.w .sup.b__________________________________________________________________________1 3 min/25° C. propylene 1.13 3.2 g 890 4,500 2 2 min/25° C. propylene 0.73 3.8 g 1,100 4,800 3 3 min/25° C. propylene 0.41 2.5 g 3,500 7,900 4 3 min/25° C. propylene 0.24 3.0 g 3,800 9,400 5 3 min/25° C. propylene 0.080 4.0 g 11,000 95,000 6 2 min/25° C. propylene 0.030 3.0 g 43,000 150,000 7 10 min/0° C. propylene 0.020 4.0 g 67,000 210,000 8 60 min/25° C. 1-hexene.sup.c 0.030 3.1 g 2,500 6,200 9 180 min/25° C. ethylene 0.17.sup.d 0.050 2.8 g 50 72,000 100,000 10 180 min/25° C. ethylene 0.32.sup.e 0.060 2.6 g 52 50,000 120,000__________________________________________________________________________ .sup.a Concentration range of catalyst = 2.65-3.05 mM .sup.b By GPC in 1,2,4trichlorobenzene vs. polystyrene standards. .sup.c Concentration of 1hexene = 6.00M .sup.d Styrene .sup.e 1Hexene The method of the invention clearly demonstrates that a silane compound as disclosed can serve as an effective chain transfer agent in the polymerization of olefins using a metallocene-containing catalyst. Therefore, the molecular weight of the resulting polymer or copolymer can be controlled by adding the appropriate amount of the silane. Furthermore, the instant method may be used to prepare novel silyl-terminated co-polymers wherein one terminus of the co-polymer is a silyl group preferably of the formula: ##STR3## or R(SiR 2 R 3 R 4 ) n in which R, R 2 , R 3 , and R 4 are defined as above. The silyl-terminated polymers or interpolymers produced according to the method of the present invention find utility in the preparation of block copolymers or star lock copolymers (e.g., when the silyl end group contains one or more reactive sites such as SiH) for application as polymer compatibilizers. They may also be used to modify the surface of plastics such as polyolefins for coating or adhesion purposes. EXAMPLES The following examples are presented to further illustrate the method of this invention, but are not to be construed as limiting the invention, which is delineated in the appended claims. All parts and percentages in the examples are on a weight basis and all measurements were obtained at 25° C. unless indicated to the contrary. The notation Ph is used to denote phenyl radical. Example 1 In the glove box, 10 mg (0.031 mmol) of [Me 2 Si(Me 4 C 5 )(t-BuN)]TiMe 2 and 28 mg (0.030 mmol) of Ph 3 C + B(C 6 F 5 ) 4 - were loaded into a 100 mL round bottom flask. On the vacuum line, 50 mL of toluene was added to the flask via a syringe under an Ar counterflow. Next, 0.20 mL (2.0 mmol) of PhSiH 3 was vacuum transferred into the flask at -78° C. The mixture was then warmed to room temperature and exposed to propylene (1 atm) while rapidly stirring for 3 min. The reaction was next quenched by the addition of 2.0 mL of methanol. The polymer was collected by filtration and then extracted with n-pentane (50 mL). The polymer was isolated by evaporating the solvent and washing the product with methanol and acetone, followed by drying under vacuum. (Yield, 4.0 g; M n =43,000, M w =150,000 by GPC; 1 H NMR (benzene-d 6 , relative intensity); δ 7.50 (Ph, 0.2), 7.20 (Ph, 0.2), 4.48 (SiH 2 , 0.2), 1.74 (--CH--, 31), 1.21 (--CH 2 --, 63), 0.96 (--CH 3 , 100), 0.78 (--CH 2 --, 0.2). 13 C NMR (C 6 D 6 , 75.5 Mhz): δ 136.2, 130.1, 129.8, 128.7, 47.4, 47.1, 46.7, 46.3, 45.9, 44.8, 32.3, 29.5, 27.8, 23.1, 21.3, 20.9, 20.6, 20.4, 20.0, 19.6, 14.5, 1.95. Example 2 In the glove box, 10 mg (0.031 mmol) of [Me 2 Si(Me 4 C 5 )(t-BuN)]TiMe 2 and 28 mg (0.030 mmol) of Ph 3 C + B(C 6 F 5 ) 4 - were loaded into a 100 mL round bottom flask. On the vacuum line, 10 mL of toluene was added to the flask via syringe under an Ar counterflow. After evacuation, 0.40 mL (3.0 mmol) of PhSiH 3 and 7.5 mL (0.060 mol) of 1-hexene were then vacuum transferred into the flask at -78° C. The mixture was then warmed to room temperature while rapidly stirring for 60 min. The reaction was then quenched by the addition of 2.0 mL of methanol. The polymer was isolated by evaporating the solvent and then washing the product with methanol and acetone, followed by drying under vacuum. (Yield, 3.1 g; M n =2,500, M w =6,200 by GPC; 1 H NMR (benzene-d 6 , relative intensity); δ 7.50 (Ph, 0.2), 7.20 (Ph, 0.2), 4.48 (SiH 2 , 0.2), 1.65 (--CH--, 9.6), 1.46 (--CH 2 --, 100), 1.13 (--CH 3 , 39). 13 C NMR (C 6 D 6 , 75.5 MHz): δ 136.5, 136.2, 135.5, 129.6, 46.0, 45.6, 40.9, 35.7, 34.6, 32.9, 32.4, 29.2, 27.2, 25.1, 23.8, 23.4, 17.5, 16.9, 16.8, 14.5, 14.4, 10.4. Example 3 In the glove box, 10 mg (0.031 mmol) of [Me 2 Si(Me 4 C 5 )(t-BuN)]TiMe 2 and 28 mg (0.030 mmol) of Ph 3 C + B(C 6 F 5 ) 4 - were loaded into a 100 mL round bottom flask. On the vacuum line, 10 mL of toluene was added to the flask via syringe under an Ar counterflow. Next, 0.70 mL (5.0 mmol) of PhSiH 3 and 2.0 mL (0.017 mol) of styrene were vacuum transferred into the flask at -78° C. The mixture was then warmed to room temperature and exposed to ethylene (1 atm) while rapidly stirring for 60 min. The reaction was quenched by the addition of 2.0 mL of methanol. The polymer was collected by filtration, and then washed with methanol and acetone, followed by drying under high vacuum. Yield, 2.78 g (50%). Polymer composition: atactic polystyrene having PhSiH 2 endcaps; M n =72,000, M w =100,000 by GPC. 1 H NMR (C 2 D 2 Cl 4 , 120° C.): δ 7.70˜6.95 (m, Ph), 4.35 (m, SiH 2 ), 2.80˜2.30 (m, --CH(Ph)--), 1.70˜1.40 (m, --CH 2 CHPh--), 1.40˜0.90 (m, --CH 2 CH 2 --). 13 C NMR (C 2 D 2 Cl 4 , 75.5 MHz, 120° C.): δ 146.3, 145.8, 129.0, 128.0, 127.8, 127.6, 125.5, 41.0, 36.8, 34.3, 31.8, 29.6, 29.4, 27.5, 25.3, 24.2, 22.5, 13.7. Example 4 In the glove box, 10 mg (0.031 mmol) of [Me 2 Si(Me 4 C 5 )(t-BuN)]TiMe 2 and 28 mg (0.030 mmol) of Ph 3 C + B(C 6 F 5 ) 4 - were loaded into a 100 mL round bottom flask. On the vacuum line, 10 mL of toluene was added to the flask via syringe under an Ar counterflow. After evacuation, 1.0 mL (6.0 mmol) of PhSiH 3 and 4.0 mL (0.032 mol) of 1-hexene were vacuum transferred into the flask at -78° C. The mixture was then warmed to room temperature and exposed to ethylene (1 atm) while rapidly stirring for 60 min. The reaction was then quenched by the addition of 2.0 mL of methanol. The polymer was collected by filtration and then washed with methanol and acetone, followed by drying under high vacuum. Yield, 2.56 g (52%), Polymer composition: poly(1-hexene) having PhSiH 2 endcaps; M n =50,000, M w =120,000 by GPC. 1 H NMR (C 2 D 2 Cl 4 , 120° C.): δ 7.50 (m, Ph), 7.20 (m, Ph), 4.49 (m, SiH 2 ), 1.18 (m, --CH--), 1.47 (m, --CH 2 CH 2 --). 1.03 (m, --CH 3 ). 13 C NMR (C 2 D 2 Cl 4 , 75.5 MHz, 120° C.): δ 136.2, 131.2, 129.7, 126.9, 45.0, 40.9, 40.3, 39.4, 39.0, 37.9, 35.3, 34.8, 34.6, 34.3, 33.9, 32.9, 32.4, 31.9, 30.7, 30.2, 29.2, 27.1, 23.7, 23.1, 20.7, 15.6, 14.5. Example 5 In the glove box, 10 mg (0.030 mmol) of rac-ethylene diindenyl titanium dimethyl and 24 mg (0.026 mmol) of PhC + B(C 6 F 5 ) 4 - were loaded into a 100 mL round bottom flask. On the vacuum line, 10 mL of toluene was added to the flask via syringe under an Ar counterflow. After evacuation, 1.0 mL (6.0 mmol) of PhSiH 3 was vacuum transferred into the flask at -78° C. The mixture was then warmed to -45° C. and exposed to propylene (1 atm) while rapidly stirring for 10 min. The reaction was then quenched by the addition of 2.0 mL of methanol. The polymer was collected by filtration, and then washed with methanol, acetone and n-hexane, followed by drying under high vacuum. (Yield, 0.040 g). The isotacticity is >94% (based on 13 C NMR assay of mmmm pentad composition). M n =8,200 by NMR. 1 H NMR (C 2 D 2 Cl 4 , 120° C.): δ 7.522 (m, Ph), 7.35 (m, Ph), 4.22 (m, SiH 2 ), 1.62 (m, (--CH--), 1.28 (m, (--CH 2 --). 0.88 (m, --CH 3 ). Example 6 In the glove box, 13 mg (0.057 mmol) of (C 5 Me 5 )TiMe 3 and 33 mg (0.036 mmol) of Ph 3 C + B(C 6 F 5 ) 4 - were loaded into a 100 mL round bottom flask. On the vacuum line, 10 mL of toluene was added to the flask via syringe under an Ar counterflow. The mixture was then warmed to 45° C. and 1.0 mL (6.0 mmol) of PhSiH 3 and 5 mL of styrene were injected via a syringe while stirring for 3 minutes. The reaction was then quenched by the addition of 2.0 mL of methanol. The polymer was collected by filtration, and then washed with methanol and acetone, followed by drying under high vacuum. (Yield, 4.48 g). The syndiotacticity is >98% (based on 13 C NMR). M n =52,000 by NMR. 1 H NMR (C 2 D 2 Cl 4 , 120° C.): δ 7.40-6.60 (m, Ph), 7.35 (m, Ph), 4.21 (m, SiH 2 ), 1.85 cm, (--CH--), 1.35 (m, (--CH 2 --). 0.90 (d, --CH 3 ). Example 7 In the glove box, 10 mg (0.027 mmol) of [Me 2 Si(Me 4 C 5 )(t-BuN)]ZrMe 2 and 28 mg (0.030 mmol) of Ph 3 C + B(C 6 F 5 ) 4 - are loaded into a 100 mL round bottom flask. On the vacuum line, 50 mL of toluene is added to the flask via a syringe under an Ar counterflow. Next, 0.20 mL (2.0 mmol) of PhSiH 3 is vacuum transferred into the flask at -78° C. The mixture is then warmed to room temperature and exposed to propylene (1 atm) while rapidly stirring for 3 min. The reaction is next quenched by the addition of 2.0 mL of methanol. The polymer is collected by filtration and then extracted with n-pentane (50 mL). The polymer is isolated by evaporating the solvent and washing the product with methanol and acetone, followed by drying under vacuum. Example 8 In the glove box, 10 mg (0.022 mmol) of [Me 2 Si(Me 4 C 5 )(t-BuN)]HfMe 2 and 28 mg (0.030 mmol) of Ph 3 C + B(C 6 F 5 ) 4 - is loaded into a 100 mL round bottom flask. On the vacuum line, 10 mL of toluene is added to the flask via syringe under an Ar counterflow. After evacuation, 0.40 mL (3.0 mmol) of PhSiH 3 and 7.5 mL (0.060 mol) of 1-hexene is then vacuum transferred into the flask at -78° C. The mixture is then warmed to room temperature while rapidly stirring for 60 min. The reaction is then quenched by the addition of 2.0 mL of methanol. The polymer is isolated by evaporating the solvent and then washing the product with methanol and acetone, followed by drying under vacuum. Example 9 In the glove box, 10 mg (0.031 mmol) of [Me 2 Si(Me 4 C 5 )(t-BuN)]TiMe 2 and 28 mg (0.030 mmol) of Ph 3 C + B(C 6 F 5 ) 4 - was loaded into a 100 mL round bottom flask. On the vacuum line, 50 mL of toluene was added to the flask via a syringe under an Ar counterflow. Next, 0.40 mL (2.6 mmol) of 1,4-disilybenzene is vacuum transferred into the flask at -78° C. The mixture is then warmed to room temperature and exposed to polypropylene (1 atm) while rapidly stirring for 5 min. The reaction was next quenched by the addition of 2.0 mL of methanol. The polymer was collected by filtration and then extracted with n-pentane (50 mL). The polymer was isolated by evaporating the solvent and washing the product with methanol and acetone, followed by drying under vacuum. (Yield, 3.0 g; M n =190,000, M w =330,600 by GPC; 1 H NMR (benzene-d 6 ); δ 7.50 (Ph, m), 7.20 (Ph, m), 4.47 (SiH 2 , m), 1.74 (--CH--, br), 1.21 (--CH 2 --, br), 0.96 (--CH 3 , br), 0.78 (--CH 2 --, br). Example 10 In the glove box, 10 mg (0.031 mmol) of [Me 2 Si(Me 4 C 5 )(t-BuN)]TiMe 2 and 28 mg (0.030 mmol) of Ph 3 C + B(C 6 F 5 ) 4 - is loaded into a 100 mL round bottom flask. On the vacuum line, 50 mL of toluene is added to the flask via a syringe under an Ar counterflow. Next, 0.50 g (3.0 mmol) of 1,3,5-trisilybenzene is transferred by syringe into the flask at -78° C. The mixture is then warmed to room temperature and exposed to polypropylene (1 atm) while rapidly stirring for 5 min. The reaction is next quenched by the addition of 2.0 mL of methanol. The polymer is collected by filtration and then extracted with n-pentane (50 mL). The polymer is isolated by evaporating the solvent and washing the product with methanol and acetone, followed by drying under vacuum. 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 and equivalents falling within the scope of the appended claims. Various features of the invention are set forth in the following claims.
There is disclosed a method for synthesizing polyolefins having a silyl group at one terminus, the method comprising reacting a monomer of an α-olefin (C≦3≦10) and a tetrasubstituted silyl radical in the presence of a metallocene catalyst.
2
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to the field of electric motors. [0003] 2. Prior Art [0004] Tecnomatic S.p.A., assignee of the present invention, has in the past made a limited number of motor stators and D.C. motor rotors using flat or square wire for the windings. In that regard, it is to be noted that as used herein, “flat” or “square” wire means wire having four substantially flat sides, each joined to adjacent sides, typically by a rounded edge. In the case of square wire, the wire may be formed in the square shape and then coated with typical winding insulation, or in some cases, pre-coated round wire has been rolled into the square shape. Rolling of round wire to a square shape has definite limits if the insulation is not to be damaged, though smaller rounded edges may be achieved if the wire is first formed by drawing or otherwise formed into the square shape and then coated. Even if the wire is first formed in the desired shape and then coated, some degree of rounding on the edges is desired for various reasons, including prevention of surface tension from pulling the coating away from the sharp edges during coating, preventing the sharp edges from cutting through the coating afterward, and preventing electric field concentration on the sharp edges to induce early breakdown. Thus, as used herein, the words “square” or “flat” or equivalent words used to describe the cross-section of an insulated copper wire are used in the general sense and are not to be construed as excluding significant or substantial rounded corners joining the substantially flat sides. “Flat” as used herein and in the claims means having two opposite sides having a greater separation than the other two opposite sides, its width being greater than its thickness. “Straight” as used herein and in the claims means substantially free of bends. Accordingly, either a flat or a square conductor may or may not be straight. “Rectangular” as used herein is a more general term meaning flat or square, square being a special case of rectangular wherein the dimension between two opposite sides is equal to the dimension between the other two opposite sides. [0005] In the prior art stators, the wire has been cut to the desired length and stripped, then bent into a hairpin shape by hand on a one at a time basis, then the two legs of the hairpin separated one hairpin at a time and hand inserted into one end of a stator, with the stripped ends of the wires sticking out of the other end of the stator being all bent all in one row uniformly in one direction and all in the adjacent row uniformly bent in the opposite direction so interconnection of wires in the two rows forming a given phase could be welded, one at a time, to provide the stator windings. However, to bring out the connections to the phases, and to interconnect phases, the corresponding wires needed to be re-bent to isolate them from the connections within each phase, something again previously done by hand. [0006] The use of the flat or square wire for the windings produces very efficient and high power to weight ratio motors because of the greater cross-section of copper that can be put into a winding slot. However, the procedure described above is slow and highly labor intensive, and not suitable for a mass produced motor. BRIEF DESCRIPTION OF THE DRAWINGS [0007] FIG. 1 shows three motor stators, one insulated but unpopulated with stator conductors, one populated with stator conductors with stator conductor ends not yet bent, and one populated with stator conductors with stator conductor ends bent using the methods and apparatus of the present invention. [0008] FIGS. 2 and 3 are cross sections of an exemplary bending fixture in accordance with the present invention. [0009] FIG. 4 is a view of part of an exemplary ring assembly used in the method and apparatus of FIGS. 2 and 3 . [0010] FIG. 5 is a side view of an exemplary bending station for carrying out the methods of the present invention. [0011] FIG. 6 is a cross section of part of the bending station illustrating part of the drive system therefor. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0012] First referring to FIG. 1 , three motor stators 20 , 22 and 24 may be seen. Stator 20 in the background of the Figure is an insulated motor stator not yet populated with stator conductors. Stator 22 , on the other hand, is populated with rectangular stator conductors 26 . The lower ends of these stator conductors are bent so that an individual stator conductor spans a fixed number of stator slots, specifically, six stator slots in an exemplary embodiment. In a typical motor stator of the type described, certain stator conductors have one side thereof longer than the other conductors to provide terminal connections for the completed stator winding. In a three phase motor, three such longer stator conductors 28 are used, all three being visible in stator 24 of FIG. 1 . [0013] The purpose of the present invention is to provide a method for twisting the upper ends (referenced to the orientation of FIG. 1 ) of the stator conductors 26 as shown in stator 22 so that the ends of most of these conductors may be welded to the end of another stator conductor a fixed number of slots away, again in the exemplary embodiment spaced six slots away. In so bending, it is to be noted that the leads 28 must be bent through a different angle so as to not interfere with the welded connection of stator conductors with adjacent stator conductors. Similarly, phase connections need to be made separate and apart from the interconnection of individual stator connectors, and accordingly, it is desired to also bend the ends of each stator conductor that is to be used for phase interconnections through a different angle than adjacent stator conductors. In the exemplary embodiment sixty stator slots are used, 6 degrees apart. Since each turn of the stator winding spans six motor slots, the ends of conductors 26 on stator 22 must each be bent to span 3 degrees. In that regard, in the exemplary embodiment there are four layers of flat stator conductors lying on top of each other in each slot with the wide portion of the rectangular conductor being circumferentially oriented. Consequently, to bend the conductors as shown in stator 24 , the conductors must be held against twisting, as otherwise they will tend to twist to bend around the thinner dimension. Further, as may be seen in FIG. 1 , the upper ends of the conductors 26 as well as conductors 28 are stripped of insulation, with the stripped ends of conductors 26 being maintained in a substantially vertical orientation, as viewed in FIG. 1 . The terminal leads 28 as well as one end of each stator conductor that is to be used for phase connections are bent through a lesser angle so as to be positioned between locations at which the ends of most stator conductors are welded together. [0014] In accordance with the present invention, the ends of all stator conductors shown in the stator 22 of FIG. 1 are simultaneously bent to the position shown on stator 24 . As shown in that Figure, the outer layer of stator conductor ends is bent in a counterclockwise direction, the next layer (the other end of the stator conductors in the outer layer) in a clockwise direction, followed by a third layer bent in a counterclockwise direction, and the fourth layer (the other end of the stator conductors in the third layer) bent in a clockwise direction. [0015] Now referring to FIGS. 2 and 3 , a cross-section of a bending fixture in accordance with the present invention may be seen. As may be best seen in FIG. 2 , the fixture includes four concentric ring-like members 30 , 32 , 34 and 36 , each having either pockets or slots 38 therein, each for receiving the end of a stator conductor as shown on stator 22 of FIG. 1 . In general the slots or pockets 38 shown in FIGS. 2 and 3 are of limited depth, though those for the input leads 28 of FIG. 1 extend along the entire height of the fixture with clearance provided as may be required for proper operation of the fixture. As used herein and in the claims to follow, a pocket may be defined by a depression or hole in a member surrounded by part of that member, and further includes a pocket defined by a slot in one member effectively closed by a surface or wall of an adjacent member. [0016] Now referring to FIG. 4 , and exemplary one of the rings 30 , 32 , 34 and 36 of FIG. 2 may be seen. While the rings are of slightly different configuration and obviously of different diameters as may be seen in FIGS. 2 and 3 , the general structure of the rings or most of them is the same. In particular, pockets or slots 38 are equally spaced around most of the periphery of the ring. However in a typical ring, one or more slots or pockets 38 ′ is mounted not rigidly to the structure of the main part of the ring, but rather is supported on a separate ring integral with, or at least attached to, protrusions 40 within slots of the main ring structure. Coil springs 44 force the protrusions 40 to the position shown after removing one stator with bent stator lead ends, with pocket or slot 38 ′ being located against the side of the main circular structure. With this general structural organization with the ends of the stator conductors in the pockets 38 and 38 ′, rotation of the base 46 of the main ring structure in the counterclockwise direction will initiate the bending of most of the ends of the stator conductors. However, pockets 38 ′ will at least initially note be positively driven, with the resistance of the ends of the stator conductors in those pockets preventing the rotation of the member holding pockets 38 ′ with the main ring against the springs 44 . Pins 42 , which are fastened to the same structure as pockets 38 , rotate therewith in slots 48 in the main ring structure until reaching the ends of the slots, after which the structure supporting pockets 38 ′ begins to rotate with the main structure supporting pockets 38 . Thus there is a lost motion between the rotation of the main ring structure holding pockets 38 and the structure holding pockets 38 ′ before the two rotate together. The angle of rotation of the lost motion before the two sets of pockets are driven in unison is the difference in angle of the bending of the regular stator conductor ends and the stator conductor ends for the phase connections and the terminal conductors. Of course, for rings rotating in the opposite direction, lost motion structure is changed to reverse the lost most direction. Also while all rings in the exemplary embodiment include the lost motion structure, this is not a limitation of the invention. [0017] Now referring to FIG. 5 , an exemplary bending station may be seen. The bending fixture 50 shown in FIGS. 2 and 3 is located in the upper region of the bending station. At the top of the bending station is a stripper 52 on which the stator will be positioned. The stripper 52 is mounted for vertical motion, being in its lowermost position during bending and then raised to extract the ends of the stator conductors, except for the entire leads, from the bending fixture 50 . The various rings 30 , 32 , 34 and 36 ( FIG. 2 ) are driven in rotation by pneumatic actuators 54 , 56 , 58 and 60 , respectively. The actuators, as well as bending fixture 50 , are supported by a table 62 structure of conventional design, the details of which are not shown. It will be noted from the Figure that the actuators alternate in direction of actuation, as of course the rings themselves alternate in direction of rotation. Each actuator in the exemplary embodiment is actually a pair of diametrically disposed actuators to provide the desired torque on the respective drive member without significant side force. [0018] FIG. 6 shows a cross-section of part of the bending station shown in FIG. 5 , generally illustrating the drive mechanism for the various rings. In particular, a central shaft 64 , configured for vertical motion, supports the stripper 52 . Concentric therewith is a tubular member 68 , driven in rotation by pneumatic actuator 60 ( FIG. 5 ). Concentric therewith is a larger tubular member 70 driven in rotation in the opposition direction by pneumatic actuator 58 . A third concentric tubular member 72 driven by actuator 56 , and finally a fourth tubular member 73 driven by actuator 54 . Thus these concentric drive members are coupled to the pneumatic actuator pairs 54 through 60 , with the innermost ring being driven by the lowermost actuator, etc. [0019] Referring again to FIG. 1 , it will be noted that as the stator conductors are bent, they bend in an arc. That arc is greatest for the ends of the stator conductors in the outermost circle and reduces to the innermost circle. Accordingly in the preferred system, in order for the four rings of the fixture to follow the arc of the respective circle of stator conductor ends, four cam assemblies 74 , 76 , 78 and 80 are provided. The lowest cam assembly 74 controls the drive member for the innermost ring 36 ( FIG. 2 ), with each additional cam assembly thereabove driving the next outer respective ring 34 , 32 and 30 , respectively. These cams raise the respective drive members and in turn raise the respective ring in a controlled manner so that the pockets in the bending fixture follow the arc of the bend, retaining the tip ends of the stator conductors in the vertical orientation without longitudinal sliding or longitudinal stressing of the stator conductors. Because the arc is somewhat different for each ring, four cam assemblies are used rather than merely one. Of course one could use a single cam assembly, or alternatively, similarly control the elevation of the stripper 52 to approximately follow the arcs, though this is not preferred because of the lack of precision in so doing. One could also simply rotate one of each pair of rings ( 30 or 32 , and 34 or 36 ) in the appropriate direction, raising all rings equally or unequally as the bending proceeds or lowering the stripper supporting the stator (or both), though this would also require the rotation of the rings through twice the angle of the preferred embodiment, and rotation of the stripper supporting the stator through half the ring rotation angle. [0020] After the ends of the stator conductors are bent as described, the actuators are depressurized or even slightly driven in the opposition direction to relieve spring-back before the extractor 52 is raised for extraction purposes. [0021] While the invention has been described with respect to an exemplary embodiments for bending the ends of rectangular stator conductors, it is to be noted that the invention is also applicable to the bending of rectangular rotor conductors. Thus there has been described herein motor stator conductor bending methods and apparatus which bends all or substantially all, or at least a majority of the free ends of motor stator conductors for interconnection with associated stator conductors, which further may include the bending of stator conductors to a different angle for phase interconnections as well as longer stator conductors for input terminals. While the invention has been described with respect to Thus while certain preferred embodiments of the present invention have been disclosed and described herein for purposes of illustration and not for purposes of limitation, 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.
Methods and apparatus for twisting rectangular rotor and stator conductor ends whereby most if not all conductor ends are bent at once, radially adjacent ends being bent in opposite directions. A lost motion member may be used to bend selected conductors through lesser angles for such purposes as phase interconnection and power leads. The rectangular conductors are retained against twisting so that flat conductors will bend about an axis perpendicular to the larger dimension of the conductor cross section. Various features of the methods and apparatus are disclosed.
8
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates generally to the detection of toxic species and, in particular, to a method and apparatus for detecting polar chemical agents and toxic species using conductive polymer coated sensing electrodes which exhibit renewable sensing characteristics enabling many repeated uses. 2. Description of the Prior Art Electrochemical reactions based on oxidation or reduction (Redox) of metals and compounds at an electrode are highly selective because of the characteristic Redox potential at which the oxidation or reduction of the electroactive species occurs. With electrochemical sensing, selection of the electrode material and electrolyte solution is very important in determining sensitivity and selectivity. Theoretical considerations for Redox electrochemistry are developed in more detail below. An electrochemical cell utilized for the detection of toxic species normally consists of a working or sensing electrode, counter electrode and a reference electrode situated such that an adjustable potential source may be connected across the sensing and counter electrodes and the current measured. This system includes an electrolyte solution containing a solvent and an electrolyte material together with a depolarizer, if desired. The solvent and electrolyte solutions from such solvents should be electrochemically stable to oxidation and reduction in the operating range of the electrochemical cell. This is necessary to give the widest possible voltage window to carry out electrochemical Redox reactions at the electrode surface without causing the decomposition of the solvent. Thus, the oxidation and/or reduction potentials of the sensing electrode must be lower than the decomposition potential of the electrolyte solvent. One such cell which utilizes a non-aqueous, aprotic electrolyte system and includes a platinum sensing electrode is illustrated and described in U.S. Pat. No. 4,555,690 to H. V. Venkatasetty, the inventor of the present invention. That application is assigned to the same assignee as the present application. Conducting polymeric materials are also known in the prior art and certain conducting polymers have also been utilized in fabricating polymer-coated platinum wire electrodes. Properties of certain polyquinoline polymers and substituted polyquinoline polymers as conductors together with their use as coatings on platinum electrodes are discussed by A. H. Schroeder, et al and Y. S. Papir, et al, respectively in abstracts numbers 543 and 544 of the Extended Abstracts of the Electrochemical Society, Spring Meeting, 1983. Although prior art sensors have been quite successful in detecting chemical agents and toxic chemicals of interest, electrochemical cells of the type described in the above-referenced U.S. Patent use platinum sensing electrodes whereas in the present invention a variety of sensing electrodes are available. Thus, one may choose the most sensitive one for detecting a particular chemical of interest. Each polymer coated electrode has its own characteristic voltammogram related to the particular polymer used. The pure platinum electrode by itself, however, does not have well defined voltammogram. SUMMARY OF THE INVENTION By means of the present invention, the problems associated with renewal or regeneration and tailoring of the Redox potential of electrochemical sensors of polar chemical agents and toxic species of interest has been solved by the provision of a method and apparatus which utilizes the properties of certain conductive polymers to produce a highly reversible and tailorable sensing system. In the preferred embodiment a thin film of a conductive polymer, preferably a polyquinoline or substituted polyquinoline polymer such as poly-2,6-(4 phenyl) quinoline is coated on a noble metal wire, such as a platinum wire, to produce the sensing electrode. A counter electrode of the same noble metal and a reference electrode of silver/silver ion (Ag/Ag+) are used. Because the Redox potential of the conducting polymers are normally higher than the decomposition potential of water and because most chemical agents and toxic species of interest dissolve more readily in organic solvents, the electrochemical cell utilizes a nonaqueous aprotic electrolyte solution such as lithium perchlorate in propylene carbonate/γ-butyrolactone or a solution of tetrabutyalammonium perchlorate and acetonitrile. These conducting polymer films show highly reversible electrochemical Redox behavior which is very sensitive to interactive chemicals present in the environment. Toxic chemicals and/or vapors on adsorbing on the electrode change the Redox potential of the sensor cell when the potential is applied to the sensing electrode. This change in potential is characteristic of the chemical species to be sensed and the current generated during Redox process is proportional to the concentration of that chemical species. The Redox potential of the coated electrode can be fine-tuned by chemical modification of the coating with corresponding change in the electrical conductivity. This is accomplished by attaching various electron withdrawing and donating groups to the pendant phenyl ring to raise and lower the Redox potential. The polymers are readily processible and can be conveniently used to coat noble metal or carbon electrodes. Cells utilizing the conductive polymer-coated electrodes and appropriate aprotic organic solvents can be used as probes for detecting various polar chemical agent species and toxic gases or vapors such as CO, NO X , HCHO, etc. BRIEF DESCRIPTION OF THE DRAWINGS In the drawings: FIG. 1 depicts a schematic diagram of an electrochemical cell which can be used in the system of the invention; FIG. 1a is a preferred form of an energizing circuit for the electrochemical cell of FIG. 1 and FIG. 2 is a graphical representation of possible cell responses to a pair of toxic species. THEORETICAL CONSIDERATIONS FOR REDOX ELECTROCHEMISTRY Prior to the detailed description, a brief recap of the theoretical considerations for Redox electrochemistry as pertinent to this invention will be presented. Considering a general electrochemical reaction where the species O undergoes reduction to species R. ##STR1## In this reduction reaction, K f represents the forward rate constant (reduction) and K b represents the reverse rate constant (oxidation). For the electrode process involving the species O and R, the rate expression can be written in the form ##EQU1## where N O and N R are the number of moles of O and R reacting per unit area per unit time. Taking into consideration the effect of applied potential to the electrode, namely the overpotential η=E-E O where E is the operating potential and E O is the equilibrium potential, the rate constant for the forward reduction reaction is given by K.sub.f =K.sub.o e.sup.-aηF/RT (3) and the rate constant for the oxidation reaction is given by ##EQU2## where K O is the rate constant at E=E O , R=gas constant, and T=absolute temperature °K. In electrochemical reaction, the rate constant can be related to current density and the net rate given by i=i c -i a , where i is the net rate and i c is the current density representing forward rate and i a is the current density representing oxidation reaction. Therefore, the net current density of an electrochemical reaction can be represented by the Butler-Volmer equation: ##EQU3## where i is the net current density, i o is the exchange current density, α is the symmetry factor, F is the Faraday constant, η is the over potential, and R and T have the usual significance. Depending on the magnitude of overpotential, the anodic or cathodic reaction predominates in reactions involving practical applications of electrochemical techniques. For electrochemical oxidation processes involving appreciable overpotentials (η>50 mV), ##EQU4## which is the well known Tafel equation. Similarly, for electrochemical reduction involving appreciable overpotential, ##EQU5## For electrochemical processes involving large overpotential, as in practical devices, mass transport of electroactive species to the sensing electrode material becomes the controlling factor. The mass-transfer processes responsible for bringing the electroactive species to the surface of the sensing electrode are diffusion controlled under the influence of a concentration gradient, migration of charged ions in an electric field and convection due to motion of the solution. One can eliminate mass transport by migration by using a high concentration of an inert supporting electrolyte, convection can be minimized by using unstirred vibration-free solution. Under these conditions, the limiting current is controlled solely by diffusion of the reacting species through the concentration gradient adjacent to the electrode. The net rate of diffusion of the species to a unit area of electrode surface at any time, t, is proportional to the magnitude of the concentration gradient. It can be represented by Fick's law of diffusion. ##EQU6## where D is the diffusion coefficient of the species, and δ is the diffusion layer thickness about the sensing electrode. At appreciably high overpotential, the region around the sensing electrode becomes depleted of electroactive species, i.e, as the C e approaches zero, the rate of diffusion becomes proportional to the concentration in the bulk of the solution, C bulk . At equilibrium, the rate of discharge of the ions is equal to the rate of diffusion to the electrode. The rate of discharge of electroactive species is equal to i/nF where i is the Fardaic current density, n is the number of electrons involved and F is the Farday constant. ##EQU7## where i 1 =limiting current density. In this expression the ratio Dδ, called the mass transfer coefficient of electroactive species, depends on the electrode geometry, the flow velocity, the diffusion coefficient of the species and the Kinematic viscosity of the electrolyte solution. These parameters can be otimized for maximum current density. DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 1 illustrates an electrochemical cell 10 consisting of a chamber 11 which is accessible to species of interest as through a semipermeable membrane 12. The chamber 11 contains a working or sensing electrode 14, a counter electrode 15 and a reference electrode 16. The working electrode is normally of platinum but may be of carbon or other suitable material. The working electrode is coated with a thin film of a conducting polymer in accordance with the present invention. The counter electrode is of the same material as the sensing electrode and the reference electrode is normally the well-known standard silver/silver ion (Ag/Ag+). An adjustable potential source 13 is connected across the sensing and counter electrodes and the current is measured in this circuit. A voltage exists but no current flows from the reference electrode to the sensing electrode. A preferred form of this energizing circuit may include an operational amplifier as shown in FIG. 1a wherein no current flows in the feedback loop from the reference electrode to the negative input of the operational amplifier. The three electrodes are internally separated by a material which also acts as a wicking material for the electrolyte. A gelled nonaqueous electrolyte solution 17 permeates and fills the chamber. Because the conducting polymer electrode surface of the working or sensing electrode 14 has an oxidation and/or reduction potential (see Table I) which is higher than the decomposition potential of water (1.23 V), it is necessary to use an aprotic organic electrolyte based system which has an oxidation or reduction potential above that of the conducting polymer composition, i.e. about 2.0 V. One such solution utilizes an aprotic organic solvent such as propylene carbonate or γ-butyrolactone and an active electrolyte such as lithium perchlorate (LiClO 4 ) which has a wide potential window so that gases sought to be detected can be oxidized or reduced in the presence of the conducting polymer without decomposing the electrolyte solution. It is well known that most toxic gases or vapors such as CO, NO 2 , HCHO and the vast majority of other chemical agents are polar compounds. In accordance with the present invention, it has been found that such polar compounds absorb preferentially on the surface of conducting polymers such as polyquinolines and substituted polyquinolines. In so doing, they change the surface properties and the Redox potential of the conducting polymer surface electrode. When the potential is applied across the electrode, the absorbed toxic material is oxidized or reduced, depending on the species, to nonpolar product(s) (e.g. CO CO 2 ). The species then desorbs from the electrode into the electrolyte solution thereby rejuvinating the electrodes for subsequent sensing of gases. If two or more toxic species are present in the gas exposed to the cell, because of their inherent molecular structure differences, they undergo oxidation or reduction at different but characteristic potentials. Hence, as illustrated in FIG. 2, they can be distinguished in their potential and their concentration by the difference in the amount of current which flows. Table I depicts some of the compounds which may be used to coat the sensing electrode in accordance with the invention. The variance in Redox potential further allows tailoring of electrodes for the improved detection of particular species of interest. TABLE I______________________________________Effect of chemical structure on conductivityand redox potential of polyquinolines. CONDUC- REDOX TIVITY POTENTIALPOLYMER S/cm EVs SCE______________________________________##STR2## 50 -1.652##STR3## 1.3 -1.603##STR4## 4.5 -1.754##STR5## 0.93 -0.9______________________________________ 1 Poly2,6-(4-phenyl) quinoline 2 Poly2,6-(4-chlorophenyl) quinoline 3 Poly2,6-(4-methoxyphenyl) quinoline 4 Poly2,6-(Nmethyl, 4phenyl) quinoline
An electrochemical method and apparatus for detecting polar toxic species is disclosed which uses a conductive polymer coated sensing electrode. The conductive polymers may be polyquinoline or substituted polyquinolines.
6
FIELD OF THE INVENTION This invention relates to fabrication of multilayered semiconductor circuit devices and more particularly to wet/dry etch techniques. The method is directed to increasing storage cell capacity by etching away some of the field oxide bird's beak at the same time a buried contact wet etch is being performed and additionally slightly etching (trenching) a storage cell active area during a polysilicon dry etch. BACKGROUND OF THE INVENTION This invention relates to wet/dry etch techniques used during the process steps used in the manufacture of multilayered semiconductor circuit devices. During these process steps, it is desired to reduce field oxide bird's beak effect in active capacitor storage cells (referred to as "storage cells" in this disclosure) and to slightly trench the storage cell active area during a subsequent polysilicon etch. Wet/dry etch refers to process steps in which selected areas on a silicon wafer are exposed by way of photolithography (photomasking) in order to remove (etch) the desired portion of these selected areas during the etching process. Wet etching uses acid chemical compounds in the liquid state, while dry etching use acid chemical compounds in the gaseous state. For example, preforming a wet etch step desired to remove an exposed nitride strip, a liquid made up of hot phosphoric acid is used to dissolve the nitride. As for the dry etch step, an exposed portion of polysilicon can be removed when presented with gaseous hydrofluoric acid. The cause of field oxide bird's beak effect (bird's beak) initiates from process steps used to isolate an active area location of a storage cell. The Local Oxidation Of Silicon (LOCOS) process, a method commonly used to isolate storage cells in a memory array during the production of a semiconductor device (LSI, VLSI, etc.), constitutes the use of thick field oxide. Initially, the silicon wafer is prepared using conventional process steps followed by growing a thin layer of initial oxide, usually silicon dioxide, over the wafer surface. Next, a layer of nitride is deposited on the wafer which is then patterned and etched away from all areas except those defined as storage cells. Field oxide is then grown over the areas that were not previously covered with nitride and as it grows it begins to encroach under the edge of the nitride layer. This oxide encroachment under the nitride is known as bird's beak that results in the actual area of the storage cell being reduced after field oxidation is complete. Therefore, reducing bird's beak becomes a critical factor in increasing the capacitance of a storage cell by maximizing the cell's active area. The invention relates to a technique to maximize storage cell active area in a high density/high volume semiconductor device fabrication process, such as for DRAMs (dynamic random access memories), by partially eliminating bird's beak without adding any process steps. The invention is applicable to all high density DRAM planar processes from the 16 Kbit to the 16 Megabit generations and beyond. It is well known for high density DRAM process/cell design, that maximum storage cell active area must be obtained as a percentage of repeating geometry area in a DRAM array. This active region/repeating region ratio determines the overall die size for a given feature size capability. Maximized storage cell active area translates directly into lower cost per bit. The storage cell active area must be large enough to insure proper sensing of data by the bitline sense amplifiers, to maintain data retention during the period of time before the cell is dynamically refreshed, and to insure strong immunity to single event upsets such as alpha particles. As geometries shrink in more advanced generation DRAMs, bird's beak becomes a dominant limiting factor to the number of cells that can effectively be packed into a given die. SUMMARY OF THE INVENTION An object of this invention is to provide a method of enlarging the active area of a storage cell both vertically and horizontally using wet/dry etching techniques during the fabrication of semiconductor devices. Another object of this invention is to perform the above mentioned etching techniques without increasing the number of process steps required. In particular it is desired to preform a wet etch to enlarge the storage cell active area at the same time a buried contact is being etched and to additionally slightly trench the storage cell active area during a first polysilicon (poly1) dry etch. Still another object of this invention is to provide better reliability in terms of less soft errors, longer dynamic refresh periods, and stronger signal strength. These and other objects of the present invention are attained by providing a method of etching the storage cell isotropically during the buried contact etch which will also allow the storage cell active area to be slightly trenched during the poly1 etch. During the buried contact etch, a special photomask is used which provides an opening over the storage cell. Because the buried contact etch is a wet etch, the oxide will be etched primarily in the lateral direction but will also etch in the vertical direction. Both lateral and vertical etching results in removinq much of the field oxide which grew under the previously deposited nitride. The end result provides a larger active area for the storage cell. Following the normal buried contact etch, poly1 is deposited and then oxide is formed (for example by TEOS deposition) over poly1. Continuing the photo/etch process, the oxide and poly1 are etched respectively. At this point, since the initial oxide deposited over the storage cell active area was removed during the buried contact wet etch, the dry poly1 etch will not only remove the exposed poly1 but also continue to etch into the storage cell active area. In the preferred embodiment, the poly1 etch uses a 25% overetch to make sure there is no residual poly left on the wafer. For example, if 5,300 angstroms of poly1 is etched, then a 25% overetch will result in an additional 1,300 angstroms of poly substrate being etched in the storage cell. The etch pattern will reflect the slope of the field oxide causing the storage cell to take on more of a dish shaped trenched appearance rather than planar and results in maximized storage cell active area. After conventional process steps used to implant transistors and storage cells are completed, the bare silicon at the storage cell is eventually covered with a second gate consisting of nitride and oxide to insulate the storage cell during poly2 deposition. The wafer is then completed by conventional methods. BRIEF DESCRIPTION OF THE DRAWINGS The drawing Figures each show a portion of a semiconductor circuit device during the fabrication process, which utilizes the present invention. The cross-sectional view of FIG. 1a shows the initial length of the proposed storage cell; The cross-sectional view of FIG. 1b shows the difference between the original length and the reduced actual length of the storage cell after field oxidation; The top view of FIG. 2 shows the location of the storage cell active area, the buried contact, and the opening in the photomask necessary for the present invention; The cross-sectional view of FIG. 3a shows the storage cell before the buried contact etch has been preformed; The cross-sectional view of FIG. 3b shows both the horizontal and the vertical distance gained by partially reducing bird's beak at the storage cell after preforming the buried contact wet etch; The cross-sectional view of FIG. 4 shows the storage cell after poly1 and oxide deposition; The cross-sectional view of FIG. 5 shows the vertical dish shaped distance gained resulting in a slightly trenched storage cell after post poly1 overetch; and The cross-sectional view of FIG. 6 shows the storage cell after it has been insulated with a thin layer of nitride and oxide. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT This invention is directed to a technique to maximize storage cell active area in a high density/high volume DRAM (dynamic random access memory) fabrication process in a sequence shown in FIGS. 1-6. These Figures show a representative device in the memory array of a dynamic random access memory (DRAM) chip. FIG. 1a shows a cross-section of a semiconductor circuit during its fabrication. A silicon starting wafer is first prepared for fabrication of semiconductor circuits, including the formation of a thin layer of oxide, known as initial oxide 15. After the formation of initial oxide 15, a dielectric such as nitride 17 is deposited over the thin oxide. The nitride 17 is then masked and etched in order to define active areas. After the field implant, a thick layer of silicon oxide, such as silicon dioxide, is grown onto the wafer 13 to form field oxide 21, as shown in FIG. 1b. The growth of silicon oxide occurs in areas which are not covered by the nitride layer 17, but tends to encroach under the edge of the nitride layer 17. The encroachment is present around the edges of the nitride 17, as indicated by dashed lines 23, where the field oxide 21 begins to "buck up" or lift (bird's beak effect) the nitride 17. Now that the silicon oxide has been grown onto the wafer all remaining nitride 17 is removed by such means as using hot phosphoric acid and water. Next, photomasking steps required in order to place buried contacts are carried out. Conventional processes use a photomask that defines the buried contacts only and consequently does not address any bird's beak reduction of the encroaching field oxide at the storage cell. It is at this point in which the applicant's inventive features come into play. During this process step a wet etch, normally using hydrofluoric acid (HF) is performed that is selective to silicon. This results in the etching away of any field oxide 21 corresponding to the photomask openings needed to locate any buried contacts required. Even though some etching occurs vertically, this etch step is directed primarily to horizontal etching of field oxide 21 until all exposed oxide is removed and the etch is blocked once silicon is reached. The disclosed invention however, uses the above mentioned wet etch to reduce bird's beak at the storage cell by adding an additional photomask opening 35 over the storage cell active area 31, as show in FIG. 2. A top view section of the wafer 13 covered by photomask 39 is shown that includes a buried contact mask opening 37 along with the addition of a storage cell mask opening 31. Using this new mask allows the subsequent wet etch to remove not only the field oxide over the area defined for the buried contact 41 but also a portion of field oxide adjacent to the storage cell active area 31 and the initial oxide covering the storage cell. FIG. 3a shows the stage the storage cell will be in before the buried contact wet etch is performed. As shown in FIG. 3a, the profile of the active area 19 is covered by the two components of oxide, the field oxide 21 and the initial oxide 15. Because photomask 39 has the additional opening over the storage cell, a portion of the field oxide 21 along with all of the initial oxide 15 will be removed during the buried contact wet etch that follows. As shown in FIG. 3b, the area of field oxide 22 is the portion of field oxide 21 that the buried contact wet etch removes along the thin layer of initial oxide 15. The area of field oxide 22 is the portion of the bird's beak removed during the buried con&act wet etch. The removal of initial oxide 15 fully exposes the underlying silicon in order to prepare for the polysilicon deposition. Following the buried contact etch, polysilicon (poly1) 41 is deposited over the wafer followed by the deposition of oxide layer 43 as shown in FIG. 4. In the preferred embodiment, low pressure chemical vapor deposition (LPCVD) is used to deposit silicon dioxide TEOS oxide or TEOS) over poly1 41 to form oxide layer 43. Following the process steps necessary for TEOS deposition, all transistors are patterned and dry etched normally using two steps. First the oxide is patterned and etched to define a gate for each desired transistor and then the oxide remaining over the transistor gate is used as a mask during the removal of the poly1. Again the advantage of having the additional photomask opening over the storage cell during the buried contact etch comes into play. Because all exposed oxide was removed during the buried contact etch the thin layer of initial oxide normally present over the storage cell is gone, thus allowing the dry poly1 etch to continue etching into the storage cell active area as the desired poly1 is being removed. This etch is primarily directed to the vertical etching of the polysilicon in the storage cell region, however horizontal etching also occurs along the width of the trench that is being cut. As shown in FIG. 5, the dish shaped portion 51 of the active area 19 shows the additional vertical distance gained in the storage cell during the poly1 overetch. As can be seen the storage cell has not taken on a trench shape giving the storage cell even more surface area. Next, conventional process steps are taken to deposit a thin layer of nitride over the storage cell to form the dielectric, followed by growing oxide over the wafer. This nitride/oxide layer is shown in FIG. 6, by a second gate layer 61 consisting of nitride/oxide covering the field oxide 21 and the active area 19 of the storage cell. The top plate of the storage cell is formed by a second polysilicon (poly2) deposition and the wafer is then completed by normal process steps. While the invention is described in terms of DRAMs, this is merely the preferred embodiment for which the inventive techniques were developed. This method of partially reducing bird's beak is also applicable to related semiconductor circuit devices, including video random access memories (VRAMs) and other multiport RAMs.
A method of partially eliminating the field oxide bird's beak over a storage cell and slightly enlarging the storage cell active area without adding any process steps is described. A photomask is used during a buried contact etch to reduce the field oxide bird's beak both vertically and horizonally. The storage cell active area is further enlarged during a first polysilicon etch step without adding process steps. At that point, the wafer is completed by existing techniques.
8
FIELD OF THE INVENTION The invention relates to optimizing compilers and methods of compiling. More particularly, the invention relates to optimizing routines used in compiling which require a data flow analysis. BACKGROUND OF THE INVENTION Compilers are generally used to transform one representation of a computer program procedure into another representation. Typically, but not exclusively, compilers are used to transform a human readable form of a program such as source code into a machine readable form such as object code. One type of compiler is an optimizing compiler which includes an optimizer or optimizing module for enhancing the performance of the machine readable representation of a program. Some optimizing compilers are separate from a primary compiler, while others are built into a primary compiler to form a multi-pass compiler. Both types of compilers may operate either on a human readable form, a machine readable form, or any intermediate representation between these forms. Many optimizing modules of compilers operate on intermediate representations of computer programs or procedures. Typically a program or procedure being translated is broken down into a series of "statements", each of which contains zero or more "operands" or "data items". A data item may be "defined", meaning that it is given a value by the statement, or "used", meaning that its value is fed into the computation represented by the statement. For example, the statement "x=y+z" defines x and uses y and z. Optimization of a program often involves locating individual statements or groups of statements which can be eliminated or rewritten in such a way as to reduce the total number of statements in the program or in a particular flow path through the program. For example, a complicated expression might be computed at two distant points within the same procedure. If the variables used in the expression are not modified to contain different values between the first and second computations, the value can be computed only once, at the first point in the procedure, and saved in a temporary location for use at the second point in the procedure, thus avoiding recomputation at the second point. This particular form of optimization is known as "common (sub)expression elimination". The main problem in optimizing a procedure is to determine at which points of the procedure various kinds of information are available. For example, to perform common (sub)expression elimination, it is necessary to know at which points the variables used by the procedure are modified. To determine such facts, a dataflow analysis is performed on the program. To perform dataflow analysis, possible paths of execution through a procedure may be represented by a control flow graph (CFG). Statements may be grouped together into basic blocks, which are maximal sequences of straight-line code. In other words, there is no way to branch into or out of a basic block except at the beginning or end. A CFG is a graph with one node for each basic block in the procedure. The CFG includes an arc from block A to block B if it is possible for block B to be executed immediately after block A has been executed. In such a case, B is called a "successor" of A, and A is called a "predecessor" of B. The CFG is generated by a forward pass through the procedure to identify basic blocks and transitions between basic blocks, and form an ordered representation of those blocks and the branches between blocks. One well-known approach for ordering the blocks in the CFG is to form a "depth first" ordering of the basic blocks of the program. This approach is described in Alfred V. Aho, Ravi Sethi, and Jeffrey D. Ullman, Compilers: Principles, Techniques, and Tools, Addison-Wesley, copyright 1986, reprinted 1988, which is incorporated by reference herein, particularly in sections 10.6 and 10.9. In a depth first ordering, each basic block is assigned a "dfo" number, with the following property: if every path from the start of the program to block Y must pass through block X, then the dfo number for X is less than the dfo number for Y, which is written dfo (X)<dfo (Y) After generating a CFG, optimization typically involves computing various properties at points of interest in the procedure, for example, the properties of the statements in each block in the CFG. Often, a matrix of binary values (bits) such as is shown in FIG. 1, is used to identify these properties. In a typical approach, there are several rows 10 in the matrix for each block in the program, each row 10 representing one property of the statements in the block. There is one column 12 in the matrix for each property of interest during optimization. At each row and column location, there is a bit which has either a "1" or a "0" value. For example, in the matrix shown in FIG. 1, each block B is associated with four rows 10, a row in[B] for identifying expressions that are available upon entry to block B, a row out[B] for identifying expressions that are available upon exit from block B, a row gen[B] for identifying expressions that are generated by statements in block B, and a row kill[B] for identifying expressions whose constituent variables are modified by statements in block B. The columns 12 in the matrix relate to particular expressions, numbered 1, 2, 3 etc. Thus, the "1" located in the row for in[B 2 ] and the column for expression 6, indicates that expression 6 is available upon entry to block B 2 ; the "0" located in the row for in[B 1 ] and the column for expression 2, indicates that expression 2 is not available upon entry to block B 1 . A difficulty that arises with the representation shown in FIG. 1, is that in practice, most of the bits in the matrix are zero (i.e., the matrix is "sparse"). In a typical case where the bits in the matrix relate to the status of particular expressions, the matrix is typically sparse because, normally, specific expressions are only used or useful in a small portion of a procedure. A large, sparse bit matrix not only consumes large quantities of space, but also requires a large amount of time to repeatedly scan in the manner needed for complex dataflow analysis. SUMMARY OF THE INVENTION The invention addresses these and other problems associated with the prior art by utilizing a skip-list data structure for representing properties of points of interest in a procedure. When sets thus represented are sparse, this data structure substantially reduces the storage space required for storing such properties, and can be scanned much more rapidly than the corresponding sparse bit matrix. Specifically, in one aspect, the invention features a method of storing properties associated with a computer procedure, in a linked list of data storage nodes. Each of the nodes in the linked list stores a property of the computer procedure, and the nodes are ordered in accordance with a predetermined property order. When a new property is associated with the computer procedure, a data storage node for the property is generated and added to the linked list. Each data storage node includes a data storage space for storing an identifier of a property, and at least a first pointer storage space for storing a pointer identifying a location of an other data storage node. The data storage space of each data storage node stores an identifier of the new property for which the node was allocated. The first pointer storage space of each data storage node stores a pointer identifying a location of an other data storage node, specifically, the pointer identifies a subsequent node in the linked list. In disclosed specific embodiments, the linked list includes data storage nodes of either a first smaller size or a second larger size; the sizes of the data storage nodes are randomly selected. The data storage nodes of the second larger size include a second pointer storage space for storing a pointer identifying a location of an other data storage node. The pointer stored into the second pointer storage space identifies the location of the next subsequent data storage node of the second larger size. In the disclosed specific embodiment, when a property is disassociated with the computer procedure, the associated data storage node becomes dispensable and is deleted. In accordance with a second aspect of the invention, a special procedure is used to initialize skip lists, prior to performing data flow analysis, to ensure that the skip list structure is not used in an inefficient manner as a result of initialization, particularly where an iterative dataflow analysis technique is used in which iterations of the analysis do not increase the membership of the property sets. Specifically, each basic block of a computer procedure is associated with sets of entry properties and exit properties, as well as property modifications caused by the basic block. The basic blocks are then selected and initialized in a predetermined order. The entry properties of the currently selected basic block, are copied from exit properties of a previously selected and processed basic block. Next, the exit properties for the currently selected basic block, are computed from the entry properties and the property modifications associated with the currently selected basic block. In the disclosed specific embodiment, the entry and exit properties are sets of expressions available upon entry and exit from the basic block, and the property modifications are expressions generated and killed by the basic block. Also, to further improve the initialization of sets for a basic block, any expressions not found in the sets of expressions available upon exit from all previously selected and processed control flow predecessors of the currently selected basic block, are removed from the set of expressions available upon entry to the currently selected basic block. In a third aspect, the invention features the structure of the linked list per se. Specifically, this structure includes a plurality of data storage nodes, each data storage node including a data storage space for storing an identifier of a property and at least a first pointer storage space for storing a pointer identifying a location of an other data storage node. The data storage space of each node stores an identifier of a first property for which the node was allocated, and the first pointer storage space of each data storage node stores a pointer identifying a location of an other data storage node, the other data storage node storing a second property associated with the computer procedure that is subsequent to the first property in a predetermined property order. In a further aspect, the invention features a computer system for compiling a computer procedure into a machine-readable representation, comprising an optimizer that optimizes the computer procedure into an optimized representation by storing and manipulating properties associated with the computer procedure in accordance with the aspects described above. In still a further aspect, the invention features a program product configured to store properties associated with a computer procedure, in a linked list of data storage nodes in accordance with the aspects described above, and a signal bearing media bearing the program, which may be a transmission type media or a recordable media. These and other advantages and features, which characterize the invention, are set forth in the claims annexed hereto and forming a further part hereof. However, for a better understanding of the invention, and the advantages and objectives attained by its use, reference should be made to the Drawing, and to the accompanying descriptive matter, in which there is described embodiments of the invention. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a data structure diagram illustrating the use in the prior art of a bit matrix to represent properties of points of interest in a computer procedure. FIG. 2 is a block diagram of a computer system consistent with the invention. FIGS. 3A and 3B are data structure diagrams illustrating skip list data structures representing the information found in two rows of the bit matrix of FIG. 2. FIG. 4 is a flow chart of specific operations performed as part of a data flow analysis using skip list data structures such as shown in FIGS. 3A and 3B. FIG. 5 is a flow chart of specific operations performed as part of initializing skip list data structures such as shown in FIGS. 3A and 3B, for the data flow analysis process of FIG. 4. FIG. 6A is a flow chart of specific operations performed as part of simultaneously scanning two skip lists and removing from one list any nodes not in the other, as part of the data flow analysis and initialization processes of FIGS. 4 and 5. FIG. 6B is a flow chart of specific operations performed as part of simultaneously scanning three skip lists and removing from one list any nodes not in one of the others, as part of the data flow analysis process of FIG. 4. FIG. 6C is a flow chart of specific operations performed as part of simultaneously scanning three skip lists and adding to one list any nodes meeting certain conditions in the other two lists. DETAILED DESCRIPTION Prior to discussing the operation of embodiments of the invention, a brief overview discussion of compilers and compiling techniques is provided herein. Overview of Compilers Compilers and the like are generally known in the art. One known type of compiler is a multi-pass optimizing compiler, which includes a front-end module for converting source code into an intermediate representation, and a back-end module which takes the intermediate representation and generates object code. The front-end module of a multi-pass optimizing compiler typically includes a lexicographic analyzer which identifies tokens or keywords in the source code, and a parser which analyzes the program statement by statement. The parser typically uses a context-free grammar to determine if program statements satisfy a set of grammar rules, and builds constructs. The parser then generates an intermediate representation using an intermediate code generator. The back-end module of a multi-pass optimizing compiler typically includes an optimizer or optimizing module which operates on the intermediate representation to generate a revised or optimized intermediate representation. Several different optimizations may be performed, including but not limited to local optimizations such as value numbering, elimination of redundant computations, register allocation and assignment, instruction scheduling to match specific machine characteristics, moving invariant code out of loops, strength reduction, induction variable elimination, and copy propagation, among others. The back-end module also includes a final code generator to generate the object code from the revised intermediate representation. A compiler may reside within the memory of the computer system upon which the object code generated by the compiler is executed. Alternatively, a compiler may be a cross-compiler which resides on one computer system to generate object code for execution on another computer system. Either type of compiler may be used consistent with the invention. One suitable back-end module for use with the invention is an AS/400 optimizing translator supplied with an AS/400 minicomputer, which is a common back-end module of an optimizing compiler. This product may be used with a front-end module such as the ILE C Compiler available from IBM, among others. It will be appreciated that other compilers are suitable for different languages and/or different hardware platforms, and may also be used in the alternative. Computer System Turning to the Drawing, wherein like numbers denote like parts throughout the several views, FIG. 2 shows a block diagram of a computer system 20 consistent with the invention. Computer system 20 is an IBM AS/400 minicomputer. However, those skilled in the art will appreciate that the mechanisms and apparatus consistent with the invention apply equally to any computer system, regardless of whether the computer system is a complicated multi-user computing apparatus or a single user device such as a personal computer or workstation. As shown in FIG. 2, computer system 20 includes a main or central processing unit (CPU) 22 connected through a system bus 21 to a main memory 30, a memory controller 24, an auxiliary storage interface 26, and a terminal interface 28. Auxiliary storage interface 26 allows computer system 20 to store and retrieve information from auxiliary storage such as magnetic disk, magnetic tape or optical storage devices. Memory controller 24, through use of a processor separate from CPU 22, moves information between main memory 30, auxiliary storage interface 26, and CPU 22. While for the purposes of explanation, memory controller 24 is shown as a separate entity, those skilled in the art understand that, in practice, portions of the function provided by memory controller 24 may actually reside in the circuitry associated with CPU 22 and main memory 30. Further, while memory controller 24 of the embodiment is described as having responsibility for moving requested information between main memory 30, auxiliary storage interface 26 and CPU 22, those skilled in the art will appreciate that the mechanisms of the present invention apply equally to any storage configuration, regardless of the number and type of the storage entities involved. Terminal interface 28 allows system administrators and computer programmers to communicate with computer system 20, normally through programmable workstations. Although the system depicted in FIG. 2 contains only a single main CPU and a single system bus, it will be understood that the invention also applies to computer systems having multiple CPUs and buses. Main memory 30 is shown storing a compiler 40 (comprising analyzer 42, parser 44, optimizer 46 and code generator 48) and operating system 32. Memory 30 also includes a workspace 50, which is shown storing a computer program in various stages of compilation, including a source code representation 52, an intermediate representation 54, an optimized representation 56 and object code 58. However, it should be understood that main memory 30 will not necessarily always contain all parts of all mechanisms shown. For example, portions of compiler 40 and operating system 32 will typically be loaded into caches in CPU 22 to execute, while other files may well be stored on magnetic or optical disk storage devices. Moreover, the various representations 52-58 of a computer program may not be resident in the main memory at the same time. Various representations may also be created by modifying a prior representation in situ. In addition, as discussed above, the front-end and back-end modules in some systems may be separate programs. It will be appreciated that computer system 20 is merely an example of one system upon which the routines may execute. Further, as innumerable alternative system designs may be used, principles of the present invention are not limited to any particular configuration shown herein. In general, the routines executed to implement the illustrated embodiments of the invention, whether implemented as part of an operating system or a specific application, program, object, module or sequence of instructions will be referred to herein as "computer programs". The computer programs typically comprise instructions which, when read and executed by one or more processors in the devices or systems in a computer system consistent with the invention, cause those devices or systems to perform the steps necessary to execute steps or generate elements embodying the various aspects of the present invention. Moreover, while the invention has and hereinafter will be described in the context of fully functioning computer systems, those skilled in the art will appreciate that the various embodiments of the invention are capable of being distributed as a program product in a variety of forms, and that the invention applies equally regardless of the particular type of signal bearing media used to actually carry out the distribution. Examples of signal bearing media include but are not limited to recordable type media such as volatile and non-volatile memory devices, floppy disks, hard disk drives, CD-ROM's, DVD's, magnetic tape, etc., and transmission type media such as digital and analog communications links. Use of Computer System Referring now to FIGS. 3A and 3B, an explanation can be provided of the skip list data structure of the kind used in accordance with principles of the present invention. The skip list illustrated in FIG. 3A stores the set of properties in[B 1 ], specifically, the set of expressions available upon entry to basic block B 1 of the computer procedure currently undergoing compilation. The skip list illustrated in FIG. 3B stores the set of properties in[B 2 ], specifically, the expressions available upon entry to basic block B 2 of the computer procedure currently undergoing compilation. As seen in FIGS. 3A and 3B, each skip list begins with an initial data storage node 60a and 60b, and includes a number of data storage nodes 62a/62b, 64a/64b, 66a/66b, 68a/68b, 70a/70b, 72a/72b etc. Each node includes a storage space 84 for storing a key for a property of the computer procedure. For example, the skip list shown in FIG. 3A, which identifies those expressions which are available upon entry to basic block B 1 , includes nodes storing the keys "3", "6", "7", "9", "12", "17", "19", "21", "25" and "26", thus indicating that the expressions associated with these keys are available upon entry to basic block B 1 . The nodes in a skip list are one of a number of sizes. Nodes of the smallest size (which will be referred to as "size 1"), such as nodes 62a and 62b, include only (a.) a storage space 84 for storing a key of a property of the computer procedure, and (b.) a storage space 86 for storing a "level 1" pointer (computer memory address) indicating the location of the next node in the skip list. Nodes of the next larger size (which will be referred to as "size 2"), such as nodes 68a and 64b, include storage spaces 84 and 86, and in addition, include a storage space 88 for storing a "level 2" pointer indicating the location of a subsequent node in the skip list. Specifically, the level 2 pointer in storage space 88 indicates the location of the next node in the skip list of at least size 2. The skip lists illustrated in FIGS. 3A and 3B also include "size 3" nodes (e.g., nodes 78a and 70b) which include, in addition to the storage spaces 84, 86 and 88 found in a size 2 node, an additional pointer storage space 90 for storing a "level 3" pointer to the next node in the skip list of at least size 3. Furthermore, the skip list of FIG. 3A includes a "size 4" node 64a, which includes, in addition to the storage spaces 84, 86, 88 and 90 found in a size 3 node, a "level 4" additional pointer storage space 92 for storing a pointer to the next node in the skip list of at least size 4. The maximum number of levels for skip list nodes is arbitrary, and may, in one embodiment, be selected based on the criteria identified by the above-referenced paper by Pugh. Skip lists terminate at a "NIL" node 82. The level 1 pointer of the last node in the skip list points to the NIL node 82. Furthermore, the level 2 pointer of the last node in the skip list of at least size 2, points to the NIL node. The level 3 pointer of the last node in the skip list of at least size 3, points to the NIL node. The level 4 pointer of the last node in the skip list of at least size 4, points to the NIL node. The keys for properties stored in a skip list, are generated so that the keys can be sorted in a predetermined, defined order, in order to simplify the process of performing a membership test of a set represented by a skip list. In the example below where the skip lists store sets of expressions related to the computer procedure, a set of keys with a predetermined ordering can be created, for example, by numbering each expression as it is encountered during a scan of the entire program in depth-first order. Then, these numbers can be used as the keys in the skip list data storage fields 84. To facilitate processing, the key for the NIL node is the highest number that can be represented in the data format used to store the keys, so that the key of the NIL node is always numerically greater than any other key in a skip list. Specific details on the use of skip lists, including the process for scanning a skip list to perform a membership test, methods for randomly selecting the size of skip list nodes, and further descriptions of the advantages of skip lists, can be found in William Pugh, Skip Lists: A Probabilistic Alternative to Balanced Trees, Communications of the ACM, June 1990, Vol. 33, Number 6, Pages 668 to 676, which is hereby incorporated herein in its entirety. Referring now to FIG. 4, the process for performing data flow analysis using the data structures discussed above can be more completely explained. Specifically, for initialization, a loop 100, 102, 104 is performed. In this loop, for each block B in the CFG (step 100), the properties gen[B] and kill[B] are computed for the block (step 102), and the next block is selected (step 104), until all blocks have been processed. This step involves adding a node to the skip lists storing gen[B] and kill[B] for each expression to be included in those sets. Details on the process for adding a node to a skip list can be found from the above-referenced paper by Pugh. Details on methods for identifying expressions to be included in gen[B] and kill[B] as part of step 102 are described in the above-referenced section of the Aho et al. book. After computing the properties gen[B] and kill[B], processing continues to step 106, in which an initial approximation of the sets in[B] and out[B] are computed for each basic block B. Details on this initialization process are set forth below with reference to FIG. 5. After the appropriate initialization has been performed, a loop including steps 108, 110, 112, 114, 116, 118, 120 and 122 is performed to make a dataflow analysis on the program and specifically the basic blocks thereof, to obtain final representations of in[B] and out[B], which can then be used in subsequent program optimizations such as common {sub} expression elimination. Each of steps 110, 112, 114, 116 and 118 is performed for each block B in the CFG (step 108) until all blocks have been processed (step 120). For each block, taken in depth-first order, a second loop including 110, 112 and 114 is performed, for the purpose of eliminating expressions that are not available upon exit of the predecessors of that block. Specifically, for each predecessor P of the currently selected block B (step 110), the skip lists storing the sets in[B] and out[P] are "walked", or scanned, simultaneously, removing from in[B] any expressions not found in out[P] (step 112). Further details on the operations performed in connection with step 112 are provided below with reference to FIG. 6A. Step 112 is repeated for each predecessor P until all predecessors have been processed (step 114). After completing this loop for each predecessor P of the currently selected block B, in step 116, it is determined whether in[B] was changed as a result of steps 110, 112 and 116. (Note that the only change that might be made to in[B] is the removal of one or more members from the set of expressions represented by in[B].) If there have been changes to in[B], then processing proceeds to step 118, in which out[B] for the same block is updated to reflect the changes to in[B]. Specifically, the skip lists which store a representation of in[B], out[B], and gen[B], are simultaneously "walked", or scanned, to identify those nodes of out[B] which should be removed as a result of the changes to in[B]. Further specific details on this process will be provided in connection with FIG. 6B. After out[B] has been updated through step 118, or immediately after step 116 if in[B] has not changed, the next block B in the CFG is selected, and processing returns to step 110. This process repeats until every block B in the CFG has been processed, at which time, processing proceeds to step 122. In step 122, it is determined whether any of the in[.] or out[.] sets, for any of the blocks in the CFG, were changed as a result of the previous pass through the blocks in the steps of loop 108, 110, 112, 114, 116, 118, 120. If so, then another pass through the blocks must be performed, and processing returns to step 108. However, if none of the in[.] and out[.] sets have changed in the previous pass, then correct final versions of the in[.] and out[.] sets have been achieved, and the data flow analysis is completed. Subsequently, the sets for in[.] and out[.] can be used in various optimizations, such as common sub-expression elimination. (Other methods may be used to select blocks to process and the order of processing, for example, a "worklist" approach could be used, in which a block is only processed if any of its predecessors changed since the last pass.) Referring now to FIG. 5, the process for calculating an initial approximation can be described in greater detail. As is noted above, the process for updating the in[.] and out[.] sets illustrated in FIG. 4, updates these sets by removing those members which are determined to be unavailable upon entry and upon exit from specific blocks. Typically, a dataflow analysis process of this kind is initialized by including all possible expressions into in[B] and out[B] for every block B in the CFG, and then using a dataflow analysis to remove expressions in an iterative manner analogous to that shown in FIG. 4, until final resulting sets of expressions are obtained. While this method of initializing the sets in[.] and out[.] is effective when these sets are represented as bit vectors as is shown in FIG. 1, where densely populated sets can be efficiently represented, this method is not effective when these sets are represented as skip lists such as is shown in FIGS. 3A and 3B, because skip lists are intended for use in representing sparsely populated sets and are not efficient in representing densely populated sets. Therefore, in accordance with principles of the present invention, a novel methodology is used to initialize the sets in[.] and out[.]. This methodology is based on the recognition that (1) the dataflow analysis conducted in accordance with FIG. 4 only reduces the number of members in these sets, and (2) it is only necessary that in[.] and out[.]. initially include all members that might be included after dataflow analysis. If a simplified analysis of the blocks B in the CFG can identify all of the members that might possibly be included in the in[.] and out[.] sets after a complete data flow analysis, then only those members that might possibly be included need be included when the in[.] and out[.] sets are initialized. To perform an appropriate initialization, therefore, in accordance with principles of the present invention, a single forward pass is made through the CFG, initializing the in[.] and out[.] sets by assuming that, in any given block B, all expressions available on exit from all control flow predecessors of block B that appear earlier in the depth-first order than block B, will be available in block B. Specifically, in a first step 130, sets are generated for an initial block Init, which by definition precedes the first block in the CFG. The sets in[Init] and out[Init] for the block Init are initialized to be empty. Then, beginning at step 132, a loop, including steps 134 through 142 is performed for each block in the CFG, taken in depth-first order. In the first step 134, the set in[B] for the current block B is copied from out[P] for a predecessor block P of the block B (where the predecessor P satisfies the requirement that dfo(P)<dfo(B)). This makes a first approximation for in[B], based on knowledge that no expression is available upon entry to block B unless it is available on exit from every predecessor P of B. Thus, the first approximation of in[B] formed by this step will include every expression that might be in the final set for in[B] after a complete dataflow analysis. After computing this initial approximation, beginning at step 136, a loop, including step 138, is performed for each remaining control flow predecessor P of block B which satisfies the requirement that dfo(P)<dfo(B). Specifically, any expressions in the approximation for in[B] which are not available upon exit from any qualifying predecessor, are removed from in[B]. Specifically, in step 138, the skip lists representing in[B] and out[B] are simultaneously "walked", or scanned, to remove from in[B] any nodes not found in out[P]. Specific details of the operations involved in step 138 are detailed below with reference to FIG. 6A. At step 140, step 138 is repeated until every predecessor P has been considered. The resulting iterative loop improves the approximation for in[B] formed in step 134 by limiting in[B] to those expressions which are available upon exit from all predecessor blocks P appearing prior to B in the depth-first ordering. After all predecessors P for a block have been processed through step 138, processing continues to step 142, at which an initial approximation of out[B] is generated. Specifically, out[B] is approximated from in[B] by adding to in[B] all expressions generated by block B (as represented by the previously-computed set gen[B]), and removing from in[B] any expressions killed by block B (as represented by the previously-computed set kill[B]). To make this approximation, the skip lists for in[B], kill[B] and gen[B] are "walked", or scanned, simultaneously, adding to out[B] any nodes found in gen[B] and any nodes found in in[B] but not in kill[B]. Details on this operation are described below in connection with FIG. 6C. After step 142, at step 144, control is returned to step 134 to process the next block B in the CFG taken in depth-first order, until all blocks B have been so processed. Once all blocks B have been processed, the sets in[B] and out[B] are appropriately initialized so that these sets have an initial approximation of their final contents which contains all of the members that might be included after a complete dataflow analysis according to FIG. 4, without including all expressions into these sets and thus incurring inefficient storage. Referring now to FIG. 6A, details of the operations performed in steps 112 (FIG. 4) and 138 (FIG. 5) to walk the skip lists of in[B] and out[P] simultaneously, removing from in[B] any nodes not found in out[P]. As a first step in this process, in step 148, the first nodes in the skip lists for in[B] and out[P] are selected. Next, in step 150 it is determined whether the end of the skip list representing in[B] has been reached, which is determined by determining whether the key of the current node of the in[B] skip list is the highest integer, which is the key of the "NIL" node 82. If so, no further processing is needed and the operation is done. However, if in step 150 the end of the in[B] skip list has not been reached, then, in step 152, it is determined whether the key in the current node in the out[P] skip list, follows the key in the current node in the in[B] skip list in the predetermined key order. If so, this indicates that the expression represented by the current node in the in[B] skip list, is not present in the out[P] skip list. (Note that if the end of the out[P] skip list has been reached, then the key of the current node in the out[P] skip list is greater than any key in the in[B] skip list, and thus the current and all subsequent nodes in the in[B] skip list should be removed and are removed by repetitions of steps 154, 156, 150 and 152, until the end of the in[B] skip list is reached.) When the current node in the in[B] skip list is not present in the out[P] skip list, processing proceeds to step 154, where the current node in the in[B] skip list is deleted. (Details on the process for deleting a node from a skip list can be found in the above-referenced paper by Pugh.) As part of deleting the current node in in[B], a flag may be set, so that it can later be determined (in step 116, FIG. 4) that in[B] as changed. After deleting the current node in the in[B] skip list, in step 156, the next node in the in[B] skip list is selected (by following the level 1 pointer of the current node to the first subsequent node), and processing returns to step 150. If, in step 152, the key in the current node in the out[P] skip list, does not follow the key in the current node in the in[B] skip list in the predetermined key order, then processing continues to step 158. In step 158, it is determined whether the key in the current node in the in[B] skip list is equal to the key in the current node in the out[P] skip list. If not, then the key in the current node in the out[P] skip list must precede the key in the current node in the in[B] skip list, and accordingly, processing proceeds to step 162, where the next expression in the out[P] skip list is selected (by following the level 1 pointer of the current node), after which processing returns to step 150. If, however, in step 158, it is determined that the keys in the current nodes in the in[B] and out[P] skip lists are equal, then the expression represented by the current node in the in[B] skip list is in out[P], in which case, the next expression in the in[B] and out[P] skip lists should be evaluated. Thus, in this case, processing proceeds to step 160. In step 160, the next node in the in[B] list is selected (by following the level 1 pointer of the current node), and then processing proceeds to step 162, where the next node in the out[P] skip list is selected. Referring now to FIG. 6B, the processing of step 118 (FIG. 4) can be described in more detail. In this step, the skip lists for in[B], gen[B] and out[B] are walked together, removing from out[B] any nodes not in either of in[B] or gen[B]. To begin this process, in step 170 the first nodes in the in[B], gen[B] and out[B] nodes are selected. Next, in step 172, the current node in the out[B] list is evaluated, to determine whether the end of the out[B] skip list has been reached (by comparing the key for the current out[B] node to the largest possible integer, which is used in the NIL node). If the end of the out[B] skip list has been reached, then processing is done. If the end of the out[B] skip list has not been reached, however, then processing proceeds to step 174, in which the key of the current node in the gen[B] skip list is compared to the key of the current node of the out[B] skip list. If the key of the current node in the out[B] skip list follows the key of the current node in the gen[B] skip list in the predetermined key ordering, then processing proceeds to step 176, and the next node in the gen[B] skip list is selected (by following the level 1 pointer of the current node in the gen[B] skip list), and then returns to step 174. This small loop including steps 174 and 176 continues to select subsequent elements in the gen[B] skip list until the key of the current element in gen[B] is either equal to or follows the key of the current node in the out[B] skip list. Once the key of the current node in the gen[B] skip list is either equal to or follows the key in the current node in the out[B] skip list, processing proceeds to step 178. In step 178, the key of the current node in the in[B] skip list is compared to the key of the current node of the out[B] skip list. If the key of the current node in the out[B] skip list follows the key of the current node in the in[B] skip list in the predetermined key ordering, then processing proceeds to step 180, and the next node in the in[B] skip list is selected (by following the level 1 pointer of the current node in the in[B] skip list), and then returns to step 178. This small loop including steps 178 and 180 continues to select subsequent elements in the in[B] skip list until the key of the current element in in[B] is either equal to or follows the key of the current node in the out[B] skip list. Once the key of the current node in the in[B] skip list is either equal to or follows the key in the current node in the out[B] skip list, processing proceeds directly to step 182. In step 182, the key of the current node in the out[B] skip list is compared to the keys of the current nodes in the gen[B] and in[B] skip lists. If the key of the current node in the out[B] skip list is not equal to either of the keys in the current nodes of the gen[B] or in[B] skip lists, then it can be determined that the expression represented by the key of the current node of the out[B] skip list is not in either gen[B] or in[B]; therefore, in this case, processing proceeds to step 184, and the current node in the out[B] skip list is deleted (details on the process for deleting a node from a skip list can be found in the above-referenced paper by Pugh). After step 184, the next element in the out[B] skip list is selected in step 186, and processing returns to step 172. However, if in step 182 the key of the current node in the out[B] skip list is equal to either or both of the keys in the current nodes of the gen[B] or in[B] skip lists, then the expression represented by the key of the current node of the out[B] skip list is in one of gen[B] or in[B]; therefore, in this case, processing proceeds to directly to step 186, and the next node in out[B] is selected, after which, processing returns to step 172. Referring now to FIG. 6C, the processing of step 142 (FIG. 5) can be described in more detail. In this step, the skip lists for in[B], gen[B] and kill[B] are walked together, adding to out[B] any nodes found in in[B] but not in kill[B]. To begin this process, in step 190 the first nodes of in[B], gen[B] and kill[B] are selected. Then, in step 192, the keys in the current nodes in in[B] and gen[B] are evaluated to determine whether these nodes are the NIL node (having the highest integer number as a key). If both of the current nodes are the NIL node, then processing is done. However, if this is not the case, then processing proceeds to step 194, in which the key of the current node in the gen[B] skip list is compared to the key in the current node in the in[B] skip list. If the key in the current node in the in[B] skip list follows the key in the current node in the gen[B] skip list, this indicates that there is at least one expression generated in the current block B, represented by a node in gen[B], that is not in in[B]; therefore, in this case, processing proceeds to step 196, where the key in the current gen[B] node is added to the end of out[B], thus including the generated expression in the set of expressions available upon exit from block B; thereafter, in step 198, the next node in gen[B] is selected, by following the level 1 pointer of the current node in gen[B], and then processing returns to step 194. This loop including steps 194, 196 and 198 is repeated until all of the elements which appear in gen[B] and are prior to the current element in in[B], have been added to the end of out[B]. (Note that because the present routine is performed during initialization of out[B], the set of expressions represented by out[B] is initially empty, and so it is not necessary to insert nodes into any middle points in out[B]. This means that the process of adding nodes can be fairly rapid. The last node of each size is stored in memory as nodes are added. Then, when adding a new node to the end of the list of size n, the last node of each height less than or equal to n has its pointer(s) updated to point to the new node. The new node then becomes the last node of size n.) Eventually, by proceeding to subsequent nodes in the gen[B] skip list, eventually a node is reached in gen[B] which has a key that does not precede the key of the current in[B] node in the predetermined key order. In this situation, processing proceeds from step 194 to step 200, where it is determined whether the current node in the in[B] skip list is the NIL node. If so, then the end of the in[B] skip list has been reached, and processing returns directly to step 192. However, if the end of the in[B] skip list has not been reached, then processing proceeds to step 202, in which the key of the current node of the in[B] skip list is compared to the key of the current node of the kill[B] skip list. The purpose of this and the following steps 204 and 206 is to determine whether the key of the current node of the in[B] skip list should be added to the out[B] skip list, and to take appropriate actions. If the key of the current node of the kill[B] skip list precedes the key of the current node of the in[B] skip list in the predetermined key order, then processing proceeds to step 204, in which the next node in the kill[B] skip list is selected (by following the level 1 pointer of the current node of the kill[B] skip list), and processing returns to step 202. This loop between steps 202 and 204 is continued until the key of the current node in the kill[B] skip list does not precede the key of the current node of the in[B] skip list. Once this occurs, processing proceeds from step 202 to step 206, in which it is determined whether the key of the current node in the kill[B] skip list is equal to the key of the current node in the in[B] skip list. If so, then the key found in in[B] is also found in kill[B]; in such a situation, the key should only be added to out[B] if the key also appears in gen[B]. Stated another way, an expression which is available upon entry to a block, but is killed by that block, will not be available upon exit from the block unless the expression is also generated by the block. Accordingly, in this situation, processing proceeds to step 212, in which the key of the current node in the in[B] skip list is compared to the key of the current node in the gen[B] skip list. If the keys are equal, then the expression represented by the current key in the current node of the in[B] skip list is generated by the current block B, and accordingly processing continues to step 214, in which a node with this key is added to the end of the out[B] skip list. Thereafter, the next node of the gen[B] skip list is selected in step 216, and the next node of the in[B] skip list is selected in step 218, and processing returns to step 192. If, in step 212, it is determined that the key of the current node in the in[B] skip list is not equal to the key of the current node in the gen[B] skip list, then the expression represented by the key of the in[B] node is not generated by the current block B. Accordingly, in this case, processing proceeds directly to step 218 to select the next node in in[B], and then returns to step 192. Furthermore, if in step 206, it is determined that the key of the current node in the in[B] skip list is not equal to the key of the current node in the kill[B] skip list, then it is determined that the expression represented by the key in the current node of the in[B] skip list is available upon entry to block B and not killed by block B. In this case, processing proceeds to step 208, in which a node is added to the end of out[B] containing the key of the current node of in[B], thus effectively adding this expression to out[B]. Next, in step 210, the key of the current node of in[B] is compared to the key of the current node of gen[B]. If the keys are equal, then processing proceeds to step 216 to select the next node in gen[B] and then (in step 218) the next node in in[B] before returning to step 172. However, if the keys are unequal, then the key of the current node of gen[B] must follow the key of the current node in in[B], and accordingly processing proceeds directly to step 218 so that the next node is selected in only in[B] before proceeding to step 192. Following the foregoing procedures, a skip list representation can be used for the sets in a dataflow analysis performed by a compiler, and in subsequent optimizations, substantially improving the efficiency of data storage as compared to the use of bit vectors. It will therefore be appreciated that the invention provides significant advantages in terms of optimization of computer procedures during compilation, resulting in more efficient compilation. It will also be appreciated that numerous modifications may be made to the disclosed embodiments consistent with the invention. For example, in some programs each block in the CFG may kill a large volume of the universe of expressions. If this is the case, then it may be advantageous to represent the sets kill[B] as bit vectors in the manner shown in FIG. 1, rather than as skip lists. If this approach is taken, then steps 202, 204 and 206 of FIG. 6C would be replaced with a single step performing a comparison of the key of the current node of in[B] to the bit vector representing kill[B] to determine whether the key of the current node of in[B] is a member of kill[B]. If so, processing would proceed to step 212, and if not, processing would proceed to step 208. Other modifications may be made to the disclosed embodiments without departing from the spirit and scope of the invention. Therefore, the invention lies in the claims hereinafter appended.
A compiler and method of compiling provide enhanced performance by utilizing a skip list data structure to store various properties of a program at points of interest in the procedure, for example, the properties of the statements in each block in the control flow graph. A special procedure is used to initialize the skip list, prior to performing data flow analysis, to ensure that the skip list structure is not used in an inefficient manner as a result of initialization. Furthermore, special procedures are used to simultaneously scan and compare two skip lists as part of solving dataflow equations.
8
FIELD OF THE INVENTION Embodiments are related to handheld flashlights powered from one or more electric storage batteries held in a battery compartment within the flashlight. BACKGROUND A handheld flashlight may be powered by one or more electric storage batteries enclosed in a battery compartment inside the body of the flashlight. When the flashlight is turned on, electrical energy stored in the batteries is converted to light energy by a light emitter such as an incandescent bulb, light emitting diode (LED), or fluorescent bulb. The batteries, light emitter, and an electrical switch may be connected in a series electrical circuit. Some flashlights include an electrical circuit for dimming the light output from the flashlight or causing light to be emitted in a flashing pattern. Some flashlights use high-capacity batteries such as lithium batteries, nickel metal hydride batteries, or other high-capacity battery technologies. High-capacity batteries may use a different battery casing to distinguish the batteries from zinc-carbon, alkaline, and rechargeable batteries. A flashlight adapted to hold a lithium battery or other high-capacity battery may have a battery compartment that is the wrong internal diameter and possibly the wrong internal length for accepting another type of battery. If a battery of the correct size and shape is not available when the high-capacity battery needs to be replaced, the flashlight may be incapable of producing a useful amount of light until the correct replacement battery is located. It may be more difficult to obtain new high capacity batteries than carbon-zinc or alkaline batteries in remote areas, after normal business hours, or during an emergency. SUMMARY An example embodiment includes a flashlight body. The flashlight body includes a light emitter coupled to the flashlight body and a battery compartment formed as an internal cavity of the flashlight body. The battery compartment may be formed with an internal diameter sized for acceptance of a primary battery. A first contact surface may be formed at an end of the battery compartment. The example embodiment further includes a battery adapter. The battery adapter includes a first end having a second contact surface coupled to the first contact surface of the battery compartment; a second end opposite the first end, the second end of the battery adapter formed with a third contact surface sized for coupling to the second contact surface; and an aperture passing through the first end and the second end of the battery adapter, the aperture formed with a diameter sized for a sliding fit of a substitute battery. The example embodiment further includes an an end cap coupled to the second end of the battery adapter. Another example embodiment includes a battery adapter for a flashlight body. The example battery adapter includes a first contact surface near a first end of the battery adapter, the first contact surface adapted for securely coupling to a corresponding contact surface on a flashlight body; a second contact surface at an end opposite the first end, the second contact surface adapted for securely coupling to the first contact surface on another of the battery adapter; and an aperture passing through the first end and the second end of said battery adapter. The aperture may be sized for a sliding fit of a substitute battery. In some embodiments, the primary battery has a battery case with a larger diameter and/or a shorter length than the battery case of the substitute battery. In other embodiments, the primary battery has a smaller diameter and/or a longer length thn the battery case of the substitute battery. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows a side view of an example apparatus embodiment including a flashlight with a removable battery adapter interposed between the flashlight body and the endcap. FIG. 2 shows a view toward a first end of the example flashlight of FIG. 1 . FIG. 3 shows a view toward a second end of the example flashlight of FIG. 1 . FIG. 4 shows a side view of the example embodiment of FIG. 1 with the example battery adapter removed. FIG. 5 is a side view of an example battery adapter. FIG. 6 is an end view of the example battery adapter of FIG. 5 . FIG. 7 is a cross-sectional view A-A of the example flashlight embodiment with the battery adapter interposed between the flashlight body back segment and the endcap, and further showing an example of a substitute battery in the battery compartment and battery adapter. FIG. 8 is an alternative cross-sectional view A′-A′ with the battery adapter removed and an example of a primary high-capacity battery enclosed within the battery compartment. FIG. 9A is a cross-sectional view B-B of an example battery adapter having threaded contact surfaces. FIG. 9B is an alternative cross-sectional view B′-B′ of an example battery adapter having contact surfaces sized for a close fit to corresponding contact surfaces on a flashlight body or on another battery adapter. FIG. 10 is a side view of two example electric storage batteries compatible with the example embodiment of FIG. 1 (Prior Art). FIG. 11 is an end view of the two example batteries of FIG. 10 , further illustrating an example internal diameter of the flashlight body in an example embodiment. FIG. 12 is another alternative cross-sectional view A″-A″ of an example flashlight embodiment with more than one battery adapter interposed between the flashlight body and the end cap and more than one substitute battery. FIG. 13 is another alternative cross-sectional view A′″-A′″ showing a battery adapter coupled to an outer surface of the flashlight body and an example primary battery that is longer and smaller diameter than the substitute battery held by the battery adapter. DESCRIPTION Some example embodiments include a flashlight operable from a primary battery retained with a battery compartment formed in the flashlight body and from a substitute battery retained in the battery compartment and slidably engaging with a battery adapter attached to an end of the flashlight body. Other example embodiments include a battery adapter having an aperture sized for a sliding fit of a substitute battery. Embodiments are advantageous for replacement of a primary battery with a substitute battery having a different diameter than the primary battery and possibly a different length than the primary battery. A primary battery may be a high-capacity electric storage battery such as, but not limited to, a lithium battery, a nickel metal hydride battery, and a high capacity alkaline battery. Examples of a substitute battery include, but are not limited to, a zinc carbon battery, an alkaline battery, and a rechargeable battery. A new high-capacity battery stores more ampere-hours of electrical energy than a new zinc-carbon battery of comparable size. FIG. 1 shows a side view of an example handheld flashlight embodiment. The example embodiment 100 includes a flashlight 102 having a body 104 coupled to an optional battery adapter 112 and an end cap 106 . When the flashlight is turned on, possibly by operation of a power switch 130 , light shines out of a first end 136 of the flashlight. In some embodiments, the flashlight may be turned on by rotation of a front segment 104 A of the flashlight body relative to a back segment 104 B. In some embodiments the front segment 104 A is separable from the back segment 104 B. The front segment 104 A and back segment 104 B may alternatively be formed as an integral unit. Batteries are retained inside the battery compartment by the end cap 106 at a second end 138 of the body 104 . When the flashlight is to be operated with a substitute battery, the battery adapter 112 is attached to the flashlight between the second end 138 of the body 104 and the end cap 106 . The battery adapter may optionally have an outer dimension 148 that matches an outer dimension 146 of the body 104 . In some embodiments, the battery adapter holds a substitute battery that has a larger diameter than the diameter of the primary battery and is therefore larger than the outer dimension of the flashlight body. When the body 104 is formed as a cylinder, the outer dimension 146 is a diameter of the cylinder. The body may alternatively be formed with a polygonal surface, for example one or more flat surfaces to prevent the flashlight from rolling when placed on another surface. FIG. 2 shows an example view toward the first end 136 . A light emitter 110 is visible behind an optional transparent window 108 . FIG. 3 shows a view toward the end cap 106 at the second end 138 of the flashlight 102 . In the example of FIG. 1 , the end cap, battery adapter, and flashlight body couple to one another by the engagement of threaded contact surfaces. The contact surfaces may alternatively be adapted for a close sliding fit or a snap fit. FIG. 4 shows an example embodiment 100 arranged for operation with a primary battery. When the primary battery is being used to power the flashlight, the end cap 106 is attached directly to the body 104 , and the battery adapter is omitted. FIG. 5 shows a side view of an example battery adapter 112 having an outer housing 113 . In the example embodiment of FIG. 5 , a first end of the battery adapter is formed with an external thread 115 selected to engage with a corresponding internal thread on the flashlight body and with the internal thread 116 on another battery adapter 112 . An internal thread 116 is formed near the second end opposite the externally threaded end. An aperture passes through the battery adapter from the first end to the second end. In some embodiments, an optional hollow sleeve 114 has an inner diameter 124 that is slightly larger than the external diameter of a substitute battery, giving a sliding fit of the substitute battery. The hollow sleeve 114 may have an outer diameter 123 matching an inner diameter 150 of the battery compartment in the body 104 of the flashlight 102 . FIG. 6 shows a view toward the internally threaded end of the battery adapter example of FIG. 5 . FIG. 7 is a cross section A-A representing an example of a substitute battery 132 in the battery compartment 142 of the flashlight body 104 . The substitute battery 132 may slidably engage the hollow sleeve 114 in the battery adapter 112 . The battery adapter holds the battery in position for a terminal 140 on the battery to make electrical contact with a battery contact terminal 126 in the body 104 . The substitute battery 132 may be too long to be contained within the battery compartment 142 . The battery adapter may extend the length of the battery compartment 142 , with the substitute battery passing through the battery adapter to contact a battery terminal contact spring 128 attached to the end cap 106 . FIG. 8 shows an alternative cross sectional view A′-A′ of the example flashlight embodiment 102 . In the example of FIG. 8 , a primary battery 134 slides into the battery compartment 142 with the terminal 140 on the battery in contact with the terminal 126 in the body 104 . The end cap 106 is directly engaged with the body 104 , the battery adapter having been omitted from the flashlight body. FIG. 9A shows a cross-sectional view B-B of the example battery adapter 112 of FIG. 5 and FIG. 6 . The internal diameter 124 of the hollow sleeve 114 fits closely into an aperture formed in the battery adapter 112 . In some embodiments the sleeve is formed as an integral part of the battery adapter. The sleeve may alternatively be omitted and the internal aperture in the battery adapter formed with an aperture having a diameter 124 corresponding to the outer diameter of a substitute battery. An exterior contact surface 150 is adapted to couple to a corresponding interior contact surface 152 on another battery adapter or on a flashlight body. FIG. 9B shows an alternative cross-sectional view B′-B- having an exterior contact surface 150 and an interior contact surface 152 adapted for securely coupling with corresponding surfaces on another battery adapter or on a flashlight body. The secure coupling may be implemented as a close sliding fit between the surfaces or by a snap fit between joined parts. FIG. 10 shows an example of a comparison between a length 122 of a battery casing for a primary battery 134 and a length 118 of a battery casing for a substitute battery 132 . FIG. 11 shows an example of a comparison between the diameter 120 of a battery casing for a primary battery and the diameter 124 of a battery casing for a substitute battery. The diameter 120 of the primary battery further represents a minimum inner diameter 144 of the battery compartment 142 . In an example embodiment, the primary battery 134 has a casing size corresponding to a CR123 lithium battery and the substitute battery 132 has a casing size corresponding to an AA alkaline, zinc carbon, or rechargeable battery. In another example embodiment, the primary battery is a D size battery and the substitute battery is a C size battery. In another example embodiment, the primary battery size is CR123 and the substitute battery size is AAA. It will be appreciated that many other size combinations are within the scope of the disclosed embodiments, with the primary battery 134 generally having a different length and/or diameter than the substitute battery 132 . FIG. 12 shows another alternative cross-sectional view A″-A″ in which more than one battery adapter 112 has been interposed between the body 104 and end cap 106 . More than one battery adapter 112 may be used when more than one substitute battery 132 has been used to replace a primary battery. FIG. 13 shows another alternative cross-sectional view A′″-A′″ in which the primary battery 134 has a smaller diameter and a greater length than the substitute battery 132 . The battery adapter may be arranged to couple to an exterior surface of the flashlight body as shown in the figure. Unless expressly stated otherwise herein, ordinary terms have their corresponding ordinary meanings within the respective contexts of their presentations, and ordinary terms of art have their corresponding regular meanings.
An example apparatus embodiment includes a flashlight operable from a primary electric storage battery and from another battery having an external casing that has a different outer diameter and possibly a different overall length than the primary battery. In some embodiments, a battery adapter extends a battery compartment to hold a longer substitute battery. In other embodiments a batter adapter holds a battery with a dimension, for example a diameter of the battery case, that is too large to allow the battery to slide into the battery compartment. Another example embodiment includes a battery adapter without a flashlight.
5
BACKGROUND OF THE INVENTION The present invention relates in general to web forming processes and, more particularly, to improved cross machine direction control of such processes. While the present invention can be applied to a variety of systems, it will be described herein with reference to a web forming machine used for making sheets of paper for which it particularly applicable and initially being utilized. Uniformity of a property of a web of sheet material can be specified as variations in two perpendicular directions: the machine direction (MD) which is in the direction of web movement during production and cross machine direction (CD) which is perpendicular to the MD or across the web during production. Different sets of actuators are used to control the variations in each direction. CD variations appear in measurements known as CD profiles and are typically controlled by an array of actuators located side-by-side across the web width. For example, in a paper making machine an array of slice screws on a headbox or an array of white-water dilution valves distributed across a headbox are usually used to control the weight profiles of webs of paper produced by the machine. Control schemes are used to control the CD actuators in order to reduce the variations at different CD locations across the web. For such schemes to succeed, it is crucial to apply control adjustments to the correct actuators, i.e., actuators that control areas of the web in which CD variations are to be reduced. Hence, the spatial relationship between the CD location of an actuator and the area of the profile the actuator influences is key to the implementation of a high-performance CD controller. The cross direction spatial relationship, between CD actuators and a CD profile, is known to those skilled in the art as “CD mapping”. FIG. 1 shows an example of a CD mapping relationship 100 wherein bumps 102 made to actuators in an actuator array are reflected in the CD profile 106 . In many sheet-forming processes, the CD mapping relationship is not a linear function. For example, on a paper making machine, the CD mapping between the headbox slice screws and weight profile is particularly non-linear near the edges of the web due to the higher edge shrinkage. The nonlinear mapping relationship is a function of various machine conditions. The relationship cannot be easily represented with a fixed explicit function. Particularly in an ongoing web making operation where the CD mapping can change either gradually or abruptly, depending on the evolution of machine conditions. Misalignment in the CD mapping can lead to deterioration in control performance. A typical symptom of mapping misalignment is the presence of sinusoidal variation patterns in both the CD profile and the actuator array. The appearance of the sinusoidal pattern is often referred to in the art as a “picket fence” pattern. The picket fence cycles that appear in both the CD profile and actuator arrays occur in the same region of the sheet and are usually of comparable spatial frequencies. The pattern is caused by the control actions being applied to the misaligned actuators. Although the mapping misalignment can be corrected by adjusting the control setup, in the past such adjustment has required manual intervention. Dependent on the frequency of CD mapping changes, the number of manual interventions may be significant. At a minimum, manual intervention requires determination of how wide the sheet is at the forming end (location of the process where the actuator array is situated) and at the finishing end (location of the process where the CD profiles are measured). While these determinations may be sufficient to satisfy processes with very minimal nonlinear shrinkage, for processes with extreme non-linear shrinkage, the scope of manual intervention may require perturbing the actuator array, at multiple locations, to determine the mapping relationship between the actuators and the CD profile. Such perturbations are typically performed with the CD control system turned off. Additionally, only a few actuators, spaced sufficiently far apart, are normally perturbed at a given time to ensure separation of the response locations in the CD profile. For a CD control system with a large actuator array, such perturbations or bumps may consume an extended period of production on the process. It is also possible to control the smoothness of the setpoints of the actuator array, i.e., to restrict the setpoint differences between adjacent actuators in the actuator array, to reduce the amplitude of the cycles. Control of smoothness is also a mechanism for making the CD control system more robust for modeling uncertainty under different process conditions and the presence of uncontrollable variations in the CD profile. Accordingly, there is a need in the art for an improved CD control for sheet making processes that can overcome changes in the mapping relationships between CD actuators and the corresponding CD profile of the web that they control. The control arrangement would correct the mappings without interruption of the CD control system and preferably would also control the smoothness of the setpoints of the actuator array instead of or in addition to corrections of the mappings. SUMMARY OF THE INVENTION This need is met by the invention of the present application wherein the CD profile of a web of material being produced is monitored and controlled to update CD control settings on-line so that changes in the operation of a machine manufacturing the web can be corrected before significant profile disturbances result. More particularly, detected variations in the profile that satisfy a search criteria, for example standard deviation between about 0.25% and about 0.75% of a web target or specification value, trigger searches for improved CD control settings. One aspect of the present invention recognizes CD actuator mapping misalignment, determines improved CD actuator control settings and applies the improved CD actuator control settings to fine tune a CD controller and thereby improve upon or correct the misalignment so that the CD controller will have improved and consistent long-term performance. Another aspect of the present invention recognizes abnormality in the smoothness of the setpoints of the CD actuators and controls the smoothness of the setpoints to again improve upon or correct such errors so that the CD controller will have improved and consistent long-term performance. The present invention encompasses the recognition and correction of either CD actuator mismatches or the CD actuator setpoint smoothness or both. Features and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows an example of CD mapping between CD actuators and their corresponding regions of influence in a CD profile; FIG. 2 is a perspective view of a paper making machine operable in accordance with the present invention; FIG. 3 illustrates selection of potential CD profile mapping misalignment regions and conversion into actuator positions in accordance with the present invention; FIG. 4 illustrates the relationship of the performance indicator J k to the CD mapping search parameter c k (center of response for the y*(k)-th actuator mapping) in accordance with the present invention; FIG. 5 illustrates the relationship of the performance indicator to the smoothness setting for global smoothing in accordance with the present invention; FIG. 6 is a block diagram of a fuzzy system update engine that can be used in the present invention; FIG. 7 shows the input membership function for the fuzzy system of FIG. 6; FIG. 8 shows the output membership function for the fuzzy system of FIG. 6; FIG. 9 shows the system rule set for the fuzzy system of FIG. 6; FIG. 10 shows the surface for the rule set of FIG. 9; FIG. 11 shows the mapping of the fuzzy rule set of FIG. 9 to the minimization of the performance indicator; FIG. 12 is a block diagram illustrating key components of a sequence controller of a working embodiment of the present invention; and FIG. 13 illustrates execution of a multiple actuator optimization aspect of the present invention. DETAILED DESCRIPTION OF THE INVENTION The invention of the present application will now be described with reference to the drawings wherein FIG. 2 schematically illustrates a paper making machine 108 having a Fourdrinier wire section 110 , a press section 112 , a dryer section 114 having its midsection broken away to indicate that other web processing equipment, such as a sizing section, additional dryer sections and other equipment well known to those skilled in the art, may be included within the machine 108 . The Fourdrinier wire section 110 comprises an endless wire belt 116 wound around a drive roller 118 and a plurality of guide rollers 120 properly arranged relative to the drive roller 118 . The drive roller 118 is driven for rotation by an appropriate drive mechanism (not shown) so that the upper side of the endless wire belt 116 moves in the direction of the arrow labeled MD that indicates the machine direction for the process. A headbox 122 receives pulp slurry, i.e. paper stock, that is discharged through a slice lip 124 , controlled using a plurality of CD actuators 126 , slice screws as illustrated in FIG. 2, onto the upper side of the endless wire belt 116 . The pulp slurry is drained of water on the endless wire belt 116 to form a web 128 of paper. The water drained from the pulp slurry to form the web 128 is called white water that contains pulp in a low concentration and is collected under the Fourdrinier wire section 110 and recirculated in the machine 108 in a well known manner. The web 128 so formed is further drained of water in the press section 112 and is delivered to the dryer section 114 . The dryer section 114 comprises a plurality of steam-heated drums 129 . The web 128 may be processed by other well known equipment located in the MD along the process and is ultimately taken up by a web roll 130 . Equipment for sensing characteristics of the web 128 , illustrated as a scanning sensor 132 in FIG. 2, is located substantially adjacent to the web roll 130 . It is noted that other forms of sensing equipment can be used in the present invention including stationary sensing equipment for measuring part or the entire web 128 and that sensing equipment can be positioned at other locations along the web 128 . As previously mentioned, misalignment of the CD mapping in the machine 108 can lead to deterioration in CD control performance resulting, for example, in sinusoidal patterns often referred to as “picket fence” patterns. Prior to the invention of the present application, correction of mapping misalignment has required manual adjustment of the control settings that can consume an extended period of production and may require disabling the CD control system during the correction. One aspect of the present invention overcomes this problem by recognizing mapping misalignment, determining improved CD control settings and applying the improved CD control settings to fine tune a CD controller and thereby improve upon or correct the misalignment so that the CD controller will have improved and consistent long-term performance. The CD control of the present application is preferably included within a controller 134 for the paper making machine 108 , although it can be included within a separate controller (not shown) coupled to the controller 134 . The following questions are addressed herein. What regions of the CD profile exhibit mapping misalignment? How should the impact on the paper making machine 108 be measured as a result of new control settings? And, how should the CD control settings be adjusted to correct the mapping misalignment and achieve improved performance? In answer, the present invention introduces an automated optimization technique that determines the locations of mapping misalignment, establishes an effective performance indicator to measure the impact of mapping misalignment, and applies a searching technique, embodied in fuzzy logic for the illustrated embodiment, to search for and identify an improved CD mapping and to apply the improved CD mapping to the machine 108 . Another aspect of the automated optimization of the present application enables a CD control system to maintain improved long-term control performance even though CD mapping misalignment occurs randomly. Long-term control performance is automatically adjusted without manual intervention and without suspension of the CD control system. Optimization is based on specific performance indicators and, in the illustrated embodiment, on a set of fuzzy rules with a fuzzy search engine executing actions in accordance with the fuzzy rule set. The present optimization technique automatically searches for an improved CD mapping and/or smoothness changes for use as continuing CD control. Thus, operators are provided with hands-free automation and long-term consistent CD control performance. The automated optimization of the present application compliments existing CD control systems by monitoring the CD profile as the web is produced and adjusting the control settings to improve the long-term performance of the CD control system. Automated searches can be performed periodically or triggered when measured web properties exceed selected thresholds (for example when the standard deviation of the overall CD profile is greater than about 0.5% of the process target or some other value within a range of about 0.25% to about 0.75%). Each time a search is run, the search engine can inhibit further searches for a period of time. Other searching and scheduling techniques will be apparent to those skilled in the art in view of the disclosure of the present application. Since the optimization search relies on operation of the CD control system, it is apparent that the CD control system cannot be interrupted or suspended during the optimization search. With the foregoing overview of the invention of the present application, a more detailed disclosure will now be provided. CD control adjustments made by a CD control system which has CD actuator mapping misalignments results in increased variability in the CD profile. Thus, in accordance one aspect of the present invention, the automated optimization determines the regions where CD actuators have mapping misalignment so that the misalignment can be corrected before the CD profile variability becomes a problem. The CD mapping misalignment regions are regions that exhibit high local variations. The CD misaligned regions are determined by transforming the CD profile into a CD variance profile, selecting the highest variation locations from the CD variance profile and mapping the highest variation locations into actuator regions. A variance profile at time t is defined as a profile of windowed variance at each CD location x of CD profile p(x,t) at time t. Let vector p(x,t) represent the full-width CD profile of a sheet property at time t. The variable x is a vector representing the contiguous CD position for the full-width web or sheet of paper. The elements of x are often referred to as the CD profile databox numbers or lane numbers. The element, p(x i ,t), of profile p(x,t) represents the sheet property at CD databox x i and at time t. The vector e(x,t) represents the full-width CD high-pass filtered profile at time t, as defined in Equation (1). e ( x,t )= p ( x,t )− Fp ( x,t )  (1) Each element, v(x i ,t) of a variance profile v(x,t) is defined as the variance of a windowed variation of CD profile e(x,t) around e(x i ,t). The variance profile v(x,t) can be given by Equation (2). s ( x,t )=└ e 2 ( x i ,t )┘ v ( x,t )= Ws ( x,t )  (2) where s(x,t)is a column vector In Equations (1) and (2), both F and W are band-diagonal square matrices. The non-zero band-diagonal elements of F define a two-sided low-pass filter window and the non-zero band-diagonal elements of W define a weighted mean. For a general case, the nonzero band-diagonal elements in W do not have to be equally-weighted. If the element w ij in the matrix W is defined by Equation (3) and r is a single-sided weighting length, then v(x i ,t) is an equally-weighted squared mean of 2r+1 points of e(x,t) around e(x i ,t). The resulting vector v(x,t), is called a “variance profile” of the CD profile p(x,t). w ij =    1 min  ( m , i + r ) - max  ( 1 , i - r ) + 1 ,    if     max  ( 1 , i - r ) ≤ j ≤ min  ( m , i + r ) ; =    0 ,    otherwise ( 3 ) where min(a,b) and max(a,b) mean the minimum and maximum values between a and b, respectively. From the CD variance profile v(x,t), a recursive method of selecting the highest variance regions in the CD profile is derived. On the h-th iteration, the method consists of the following steps: 1. Selecting the databox x*(h), where v(x*(h),t) is the largest among all elements of v(x,t). 2. Adding the selected x*(h) to an ordered set X X={x *(1), x *(2), x *(3), . . . x *( h )} 3. Zeroing all entries in v(x,t) that are within l elements to either side of x*(h) (subject to the boundary of 1 and m). The typical minimum length l is specified to be equal to twice the weighting window length r (2r), of the weighting matrix W.   x l ( h )=max(1 ,x *( h )− l ) x u ( h )=min( m,x *( h )+ l ) [ v ( x l ( h ), t ) . . . v ( x u ( h ), t )]=[0 . . . 0] l×[x u (h)−x l (h)+1]   (4) 4. Iterate back to 1 or terminate the described process if all elements of v(x,t) are finally zeroed. Once the process is terminated at the h-th iteration, the ordered set X contains a total of h elements. In the final stage of determining potential actuator mapping misalignment regions, the selected databoxes in the ordered set X are mapped into actuator indices based on the current CD mapping relationship where the current CD mapping relationship is defined by two vectors, b l (y) and b u (y). The variable y=[y s ] is a vector of actuator indices where y s is referred to as the s-th actuator. The elements b l (y s ) and b u (y s ), from the vectors b l (y) and b u (y), represent the lower and upper bounds of the s-th actuator mapping expressed in databox units, respectively. Let k be the index of element x* in the ordered set X, i.e. x*(k)εX where 1≦k≦h, the actuator index y*(k) associated with x*(k) is found by searching each element of y so that x*(k) falls between the values of b l (y*(k)) and b u (y*(k)). The ordered set Y of y*(k) is obtained from the equation: Y={y *( k )|where y *( k ) satisfies b l ( y *( k ))≦ x *( k )≦ b u ( y *( k )) for each x *( k )ε X}   (5) The above selection of the regions that have potential CD profile mapping misalignment is illustrated in FIG. 3 . Once these regions have been identified, a search for an improved CD mapping is performed. In the present application, a performance indicator is established for each actuator region to evaluate the effectiveness of changes of the actuator mapping alignment. The performance indicators are expressed as quadratic functions of CD profile and actuator setpoints around the regions identified in sets X and Y respectively. As previously defined, the vector e(x,t) represents the full-width CD high-pass filtered profile, at time t. Additionally, let us use the vector u(y,t) to represent the setpoints of the actuator array, at time t. Also, as previously defined, the variable y is an actuator index vector. With the objective of optimizing the local performance of the CD profile, it is essential to evaluate only a local region of the vectors e(x,t) and u(y,t). To establish a local region of e(x,t) and u(y,t), the following definitions are applied to the development of the mapping performance indicator: a kd ={s| all actuator indices s satisfies max(1,y*(k)−d)≦s≦min(n,y*(k)+d)} is a range of actuators around the y*(k)-th actuator, where d is the actuator range around the y*(k)-th actuator and n is the total number of actuators. b u (y*(k)) is the upper bound of the y*(k)-th actuator mapping, expressed in databox numbers b l (y*(k)) is the lower bound of the y*(k)-th actuator mapping, expressed in databox numbers b kd ={i| all databox indices i satisfies b l (y*(k)−d)≦i≦b u (y*(k)+d)} is a range of databox numbers corresponding to the range of actuators in a kd c k is the center of response for the y*(k)-th actuator, expressed in databox numbers With the above variable definitions, the local segment of e(x,t) and u(y,t) associated with the window around the y*(k)-th actuator can be defined as u kd =[u(y s ,t)]where sεa kd is the local segment of actuator setpoint array corresponding to the range of actuators in a kd , u kd is a column vector. e kd =[e(x i ,t)] where iεb kd is the local segment of CD high-pass profile, e(x,t), corresponding to the range of databoxes in b kd , e kd is a column vector. and the performance indicator for mapping optimization can be expressed as the quadratic function J k J k ( e kd ,u kd ,c k )= e kd T Q kd T Q kd e kd +λ kd u kd T R kd T R kd u kd   (6) In the performance indicator of equation (6), Q kd and R kd are weighting matrices and the variable λ kd is a weighting factor. For mapping optimization, the center of response of the y*(k)-th actuator and its adjacent actuators are adjusted. Typically, the parameter search adjusts c k directly. The centers of response of actuators adjacent to the y*(k)-th actuator are linearly interpolated between y*(k−1) and y*(k), and between y*(k) and y*(k+1). Additionally, the range parameter d is typically common for any actuator y*(k) being optimized. Therefore, without loss of generality, there is no confusion by eliminating the subscript d from equation (6). With this simplification, the performance indicator of equation (6) can be written as: J k ( e k ,u k ,c k )= e k T Q k T Q k e k +λ k u k T R k T R k u k   (7) In the performance indicator of equation (7), if λ k = 0   Q k = I l k × l k l k ,    where     l k = length     of     e k ( 8 ) where I l k ×l k is the identity matrix, then J k represents the localized variance of the CD high-pass filtered profile e(x,t), over the range specified by e k . If λ k ≠ 0   R k = [ - 1 1 0 ⋯ 0 1 - 2 1 ⋰ ⋮ 0 ⋰ ⋰ ⋰ 0 ⋮ ⋰ 1 - 2 1 0 ⋯ 0 1 - 1 ] ( 2  d + 1 ) × ( 2  d + 1 )   Q k = [ q j ] l k × l k ( 9 ) where q j is a column vector in the j-th column which specifies a band-pass filter symmetric about the j-th element q jj in q j , then J k represents a measure of a localized streak pattern for both e(x,t) and u(y,t). In this case, since J k reflects the severity of the localized streak pattern, J k could be called the “streak index at k”, or simply a “streak index”. In the most general case, both the Q k and R k matrices are constructed as band-pass matrices, to isolate a specific frequency band of variations in the CD profile and actuator setpoint array, respectively. For the general case, the term “streak index” can mean streak patterns at different frequency bands. Applying the quadratic performance indicator defined in equation (7) to process data, the relationship of the performance indicator J k to the CD control setting c k is displayed in FIG. 4 . Given the performance indicator of equation (7) and the result illustrated in FIG. 4, the mapping optimization for the y*(k)-th actuator can be stated as: c k opt = arg     min c k ∈ [ 1 , m ]  { J k  ( e k , u k , c k ) } ( 10 ) where the notation “ arg     min ω ∈ Ω  { J } ” means “the argument that minimizes the function J subject to the argument ω that is an element of Ω”. The other objective of the present application, i.e., optimizing or improving the long-term performance of a CD control system, is to minimize or reduce the variance of the full-width CD profile. Similar to local optimization, the performance indicator for the full-width performance is characterized by both the CD profile and the actuator setpoint array at a given value of a full-width optimization parameter. However, this performance indicator is defined for the entire CD profile and the entire actuator setpoint array. The performance indicator for the full-width optimization can be expressed as the quadratic function J: J ( p,u ,β)= p T Q T Qp+λu T R T Ru   (11) In the performance indicator of equation (11), Q and R are weighting matrices and λ is a factor used to adjust the weighting of the actuator setpoint array. In equation (11), if λ = 0 ,  Q = I m × m m ,    m = length     of     p , ( 12 ) where I m×m is the identity matrix, then J represents the variance of the entire CD profile p(x,t). If λ = β ,  R = [ - 1 1 0 ⋯ 0 1 - 2 1 ⋰ ⋮ 0 ⋰ ⋰ ⋰ 0 ⋮ ⋰ 1 - 2 1 0 ⋯ 0 1 - 1 ] n × n ,  Q = [ q j ] m × m , ( 13 ) where q j is a column vector in the j-th column which specifies a band-pass filter symmetric about the j-th element q jj in q j and matches the frequency band captured by the matrix R. For this case, the variable β serves the function of a weighting factor for the global smoothing of the actuator setpoint array. Applying the quadratic function defined in equation (11) to process data, the relationship of the performance indicator J to the global smoothing β is displayed in FIG. 5 . Given the performance indicator of equation (11) and the result illustrated in FIG. 5, the objective for full-width performance optimization can be stated as: β opt = arg     min β ∈ ℜ +  { J  ( p , u , β ) } ( 14 ) A number of known optimization methods can be used in the present invention to optimize the performance indicators, including genetic algorithm and the gradient method. The gradient method is used in the illustrated embodiment of the performance indicators of Equations (7) and (11). As is well known, the gradient method is an iterative technique that adjusts the value of a parameter to improve the value of the performance indicator on successive iterations. For minimization, the parameter is adjusted to reduce the value of the performance indicator. The basis equation for this optimization method is given in Equation (15). χ( t+T )=χ( t )+α( t )δ( t )  (15) The references t and t+T are used to denote values at the current and the next execution cycles of the basis equation, respectively. χ is the parameter being adjusted to optimize the performance indicator. α is a positive adjustment magnitude used for changing the current value of χ. δ is the adjustment direction, with values of positive one (+1), negative one (−1) and zero (0), for applying the magnitude α to the current value of χ. The δ values of positive one (+1), negative one (−1) and zero (0) translate to increasing, decreasing and not changing the current value of χ by the magnitude α, respectively. When applying the gradient method to minimize a performance indicator J, nine generalized adjustment rules can be stated for the parameter χ. 1. If the change in parameter χ is positive (Δχ>0) and the change in performance indicator J is positive (ΔJ>0), then the current value χ is decreased by α. 2. If the change in parameter χ is positive (Δχ>0) and the change in performance indicator J is negative (ΔJ<0), then the current value χ is increased by α. 3. If the change in parameter χ is negative (Δχ<0) and the change in performance indicator J is negative (ΔJ<0), then the current value χ is decreased by α. 4. If the change in parameter χ is negative (Δχ<0) and the change in performance indicator J is positive (ΔJ>0), then the current value χ is increased by α. 5. If the change in parameter χ is positive (Δχ>0) and the performance indicator J is not changed (ΔJ=0), then the current value χ is not changed. 6. If the change in parameter χ is negative (Δχ<0) and the performance indicator J is not changed (ΔJ=0), then the current value χ is not changed. 7. If the parameter χ is not changed (Δχ=0) and the change in performance indicator J is negative (ΔJ<0), then the current value χ is not changed. 8. If the parameter χ is not changed (Δχ=0) and the change in performance indicator J is positive (ΔJ>0), then the current value χ is not changed. 9. If the parameter χ is not changed (Δχ=0) and the performance indicator J is not changed (ΔJ=0), then the current value χ is not changed. For the case of CD actuator mapping optimization, χ is the CD map setting c k (center of response for the y*(h) th actuator mapping). For the case of full-width optimization, χ is the setpoint global smoothness setting β. The mathematical definition of δ, Δχ and ΔJ is given in Equation (16). The references to t and t−T are used to denote values at the current and the previous execution cycles of the basis equation, respectively. δ( t )=sign of (−ΔχΔ J ) Δχ=χ( t )−χ( t−T ) For mapping: Δ J=J k ( p k ( t ), u k ( t ), c k ( t ))− J k ( p k ( t−T ), u k ( t−T ), c k ( t−T )) For full-width performance: Δ J=J ( p ( t ), u ( t ),β( t ))− J ( p ( t−T ), u ( t−T ),β( t−T ))  (16) Given the stated rules, in the illustrated embodiment, adjusting the value of χ is achieved by a fuzzy logic system with two inputs and one output. The fuzzy logic system provides variable adjustment magnitudes and nonlinear adjustment for the optimum value of χ. For this system, the input and output linguistic variables are: Input Linguistic Variables ΔJ: “change in performance indicator J” Δχ a : “actual change in control setting χ” (c k or β) Output Linguistic Variable Δχ r : “requested change in control setting χ” (c k or β) The fuzzy system used to model the gradient method is illustrated in FIG. 6 . Seven coefficient triangular membership functions are used to define the linguistic values of the inputs and output, see FIGS. 7 and 8 which illustrate the selection of the membership functions and the assignment of the linguistic values. FIG. 7 shows the input membership function 140 and FIG. 8 shows the output membership function 150 . The center coefficients (coefficient # 4 ) of the membership functions 140 and 150 are set to zero to capture the notion of “no change”. Coefficients 1 through 3 of membership function 140 are set to negative values to capture the notion of “negative” changes in χ and J; while coefficients 5 through 7 are set to positive values to capture the notion of “positive” changes in χ and J. Coefficients 1 through 3 of membership. function 150 are set to negative values to capture the notion of “decrease” in the value of χ; while coefficients 5 through 7 are set to positive values to capture the notion of “increase” in the value of χ. The absolute magnitudes of the non-zero coefficients are scaled to achieve the desired resolution for the inputs and output. Since the change in χ (c k or β in the invention of the present application) is both an input and an output linguistic variable, the same linguistic values are used for Δχ a (actual change) and Δχ r (requested change) membership functions. With the specified input and the output membership functions, the nine generalized rules described above are used to develop a 49 entry fuzzy rule set. To model the gradient method, the rule set is illustrated in FIG. 9 . In the fuzzy rule set of FIG. 9, if the center row and column are considered the zero axes, then the rule set can be reviewed as having four (4) quadrants: the 1 st quadrant 160 implements generalized rule 1; the 2 nd quadrant 162 implements generalized rule 2; the 3 rd quadrant 164 implements generalized rule 3; and, the 4 th quadrant 166 implements generalized rule 4. The center column 168 implements generalized rules 5 and 6. The center row 169 implements generalized rules 7 and 8. The origin 171 , or crossing of the center column 168 and center row 169 , implements generalized rule 9. In the four quadrants, the sign of the output linguistic values are appropriately chosen to generate adjustments of χ in the correct direction, and the output linguistic values are varied to generate variable adjustment magnitudes α. This selection produces large adjustments in χ for activation of rules far from the origin 171 and small adjustments in χ for activation of rules near to the origin 171 . The surface 170 for this rule set is illustrated in FIG. 10 and the mapping of the fuzzy rule set to the minimization of the performance indicator is illustrated in FIG. 11 . Implementation of the illustrated embodiment of the present application includes two optimizations. The first optimization is performed on the CD map setting c k and the second optimization is performed on the full-width performance setting β. Of course one or the other could be optimized alone in accordance with the present invention. The goal of the optimization is to minimize a performance indicator defined for the specific control setting. In a working embodiment of the invention of the present application, a sequence controller 180 manages the optimization searches. A block diagram illustrating the key components of the sequence controller 180 is illustrated in FIG. 12 . The optimization manager 01 schedules execution of the mapping region selector 02 , the performance indicator 03 , and the fuzzy system 04 . The mapping region selector O 2 evaluates the CD profile to reveal regions of the sheet that potentially need mapping improvements. The mapping optimization regions are selected in accordance with the definition of the ordered set of actuator indices Y. Of course, the present invention also permits manual selection of actuators for Y by bypassing execution of the mapping region selector O 2 . The selection of the ordered set Y is performed at initiation of the mapping optimization and the CD actuators in Y become the focus of the mapping optimization for obtaining a more effective alignment of the CD profile to the CD actuator array. Dependent on the subject of the optimization, either mapping or full-width performance, the performance indicator O 3 computes the performance indicator, J k or J, and the fuzzy system O 4 adjusts the appropriate control setting, c k or β, based on the fuzzy rule set illustrated in FIG. 9 . The control setting, c k or β, is adjusted for a specified number of iterations. The performance indicator and fuzzy system O 3 and O 4 are executed on each of these iterations. In addition to scheduling the execution of the mapping region selector O 2 , the performance indicator O 3 and the fuzzy system O 4 , the optimization manager O 1 of the sequence controller 180 oversees the operations of initiating the optimization process, selecting the CD map setting c k 's to adjust, and terminating the optimization process. Initiation of parameter optimization and adaptation is triggered either manually or automatically. For automatic triggering, the CD profile variability is continually monitored and compared against a triggering threshold. The optimization is automatically initiated for sustained profile variability in excess of the triggering threshold, for example when the standard deviation of the overall CD profile is greater than about 0.5% of the process target. Upon initiation, the current profile variability and control settings, c k and β, are saved as an initial reference for performance comparison and control setting restoration as needed. For CD mapping optimization, the optimization is performed at actuator locations y* specified in the actuator ordered set Y, see FIG. 3 . Since mapping optimization is performed on multiple actuator c k 's, a method of exercising multiple actuator mapping adjustments is employed to accelerate the optimization process and to substantially eliminate interaction between actuators involved in a search, i.e., search actuators. To this end, a multiple actuator optimization divides the actuators in Y into two alternating or interleaved banks. That is, consecutive actuators in the first bank are separated from one another by actuators in the second bank. The optimization is simultaneously performed for all actuators in one bank while holding the CD map setting c k of the actuators in the other bank fixed. The optimization of the c k 's for a given bank is performed for the specified number of iterations, then the optimization is switched to the c k 's for the alternate bank for the same number of iterations. Two separate adjustment iteration counts are specified. One iteration count specifies the number of adjustments performed on the actuator c k in each of the two banks and the other iteration count specifies the number of times the optimization alternates between the actuator banks. For example, if ten adjustment iterations are specified per bank of actuators and three iterations are specified for alternating between the actuator banks, ten adjustment iterations are performed on the actuators of the first bank while holding the second bank fixed, ten adjustment iterations are performed on the actuators of the second bank while holding the first bank fixed, ten adjustment iterations are conducted on the actuators of the first bank while holding the second bank fixed, etc. until thirty adjustment iterations have been performed on all actuators in Y. In this way, the mapping optimization is alternated between the two (2) banks. Execution of the multiple actuator optimization method is illustrated in FIG. 13 . Execution and termination of parameter optimization and adaptation can be triggered manually or automatically. Automatic termination of either the mapping or smoothness optimizations can be controlled using a variety of conditions, two exemplary conditions include: improvement of the profile variability by a specified percentage of the initial reference level; and, exhaustion of all adjustment iterations (or search tries) specified for the optimization as described above. To ensure that the control performance is being improved as much as possible during a given optimization operation, a series of CD profile improvement percentages (of the initial reference level) are selected to correspond to the control setting adjustment iterations. The improvement percentages are selected to have a decaying magnitude. That is, the improvement percentage required on the first adjustment iteration is larger than the improvement percentage required on the last adjustment iteration. For example, a 50% improvement may be required on the first adjustment iteration and a 20% improvement may be required on the last adjustment iteration. To further clarify, the improvement percentage for each subsequent iteration can be reduced by a factor α (0≦α≦1, for example α equal to ½) times the difference between the current percentage and the final percentage. Hence, on the first iteration if the improvement percentage is 50%, on the second iteration the improvement percentage would be 35% (35=50−½ of (50−20)), on the third iteration the improvement percentage would be 27.5% (27.5=35−½ of (35−20)), etc. On any given iteration, if the CD profile variability is improved by the selected percentage, the optimization is terminated and the requested control setting, c k or β, adjustment is kept. If all specified adjustment iterations are exhausted with no significant improvement, the optimization is terminated and the control setting, c k or β, is restored to the initial reference value. The automated optimization technique for CD control of the present application, as described above, results in a number of advantages. Some of which are as follows: 1. The automated optimization scheme removes a root cause of CD control performance deterioration. For CD control, the fundamental operation of mapping is essential for performance. 2. The present invention identifies profile regions having a high potential for improvement of the CD mapping. CD mapping is a functional means of describing a complex relationship between the CD profile and the CD actuator array. Local profile variation gives a performance measure of mapping for the CD actuator array. 3. The performance indicator of the present invention considers all the process variables that give a good measure of performance for adjusting and evaluating a control setting. The main objective of the present invention is minimization of the CD profile variability. Minimization of the CD control elements (actuator array) prevents unnecessary delivery of control actions to the process, which is likely to amplify CD profile variations in other spatial frequencies. 4. Uses a priori knowledge of the process and the control, and incorporates them into a fuzzy rule set. 5. The automated optimization technique is a complimentary function of the CD control system. The CD actuator mapping and full-width performance optimizations provide robustness to an existing CD control system by updating control settings of essential functions in a CD control system. 6. The automated optimization technique provides continuous monitoring and periodic execution of the control setting optimization and adaptation. The periodic execution is needed to handle the dynamic behavior of the sheet manufacturing process, which can change the CD mapping at any time. The sheet manufacturing process runs continuously, with periodic maintenance shutdowns. These shutdowns can span one month or longer, the periodic execution of control setting optimization is needed to compensate the CD control system for degradation in the production machinery. The described optimization scheme of the present application provides hands-off and interruption free operation of a paper making machine. The continuous monitoring nature of the optimization method schedules the searching without manual intervention while permitting manual initiation if desired. The optimization search relies on operation of the CD control system to produce the performance of the search parameter so that operation of the CD control system is not interrupted or suspended during operation of the invention of the present application. Having thus described the invention of the present application in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
The CD profile of a web of material being produced is monitored and controlled to update CD control settings on-line so that changes in the operation of a machine manufacturing the web can be corrected before significant profile deviations from a desired CD profile target result. Detected variances in the profile that satisfy a search criteria initiate searches for improved CD control settings. The CD control of the present application recognizes CD actuator mapping misalignments, determines improved CD control settings and applies the improved CD control settings to fine tune a CD controller and thereby improve upon or correct mapping misalignments. The CD control of the present application also recognizes non-smoothness of the setpoints of the CD actuators and controls the smoothness of the setpoints. Recognition and correction of either CD actuator mapping misalignments or CD actuator setpoint smoothness or both can be performed by the automated optimization of the present application.
3
The invention relates to a built-in pest control system for the distribution and release of pesticide within walls and other concealed areas of buildings. BACKGROUND OF THE INVENTION The control of bugs, rodents and other pests within buildings is usually done by spraying or depositing pesticides along baseboards and other exposed areas or by spraying the same into those concealed areas readily accessible through cracks and crevices. Such application of poisonous substances presents a hazardous potential for harmful contact with humans and pets, either directly or through the intermediary of contacted foodstuffs or utensils. Those substances may also leave unsightly stains on carpets and baseboards. Furthermore, the residual effectiveness of pesticides thus applied may be reduced by exposure to the degenerating effects of UV light and moisture. Commercially available pest control products for crack and crevice application, include aerosols such as those available from Whitmire Research Laboratories, St. Louis, MO, designed for direct injection into wall voids and other concealed places through expansion joints, electrical outlet openings and the like, using short lengths of tubing that affix to the spray nozzle of the can. Crack and crevice injection chemicals can be stronger and, thus, more effective than exposed surface application materials; however, care must be taken to avoid depositing the same onto exposed surfaces or introducing the more potent material into the air. Moreover, there is a danger that the stronger materials may be used by nonprofessionals as contact sprays for exposed surface treatment, contrary to directions and despite nonapproval for such usage. Ramsey U.S. Pat. No. 3,676,949 proposes an insecticide distribution system in which insecticide is introduced under pressure into piping preinstalled through the studs, joists, rafters and built-ins of buildings, and released through preset pressure responsive nozzles, each positioned to spray a different otherwise inaccessible interior building location. Installation of piping is preferably to be done during building construction. The pipes are run in circular loops, having a return line back to the point of entry. Insecticide is run under pressure into the entry port, with the exit port closed off. Pressure is built up in the pipe, until the pressure has built up to the release pressure of each valve. The valves then open, and insecticide is sprayed into the wall void or other concealed location of the valve. Once the material has been completely distributed throughout the house, the piping lines are cleaned out by forcing air or a combination of air and solvent through the piping. While Ramsey recognizes the benefit of distributing and releasing pest control materials by means of a conduit system to areas that would otherwise be inaccessible following completion of construction, the rigidity of the piping utilized, the return loop requirement needed for prerelease pressurizing, and the use of individual pressure valves provides an unnecessary complexity to the system that presents a burden both during and after installation. The valves ("nozzles") are, for example, mounted in place by drilling and tapping after installation of the piping itself. This procedure takes time, costs money, and interferes with the construction schedule. Moreover, the nozzles have moving parts that may block in either open or closed position, both of which will interfere with proper operation, but will be difficult to remedy because of subsequent inaccessibility. Also, it will be difficult to know which of the concealed nozzles is the offending one. Lundwall U.S. Pat. No. 4,028,841 relates to a distribution system for vermin control, also facilitated by the use of pipes disposed throughout a building. The Lundwall system employs pipes having periodic openings for distribution of a fluid vermin control material throughout the walls and below ground level. Distribution is effected by means of a pressurizing pump controlled by a solenoid valve, which automatically and periodically pumps material from a storage reservoir under pressure through the openings. Lundwall recommends the use of chlordane, a highly toxic material having a long residual life. The Lundwall approach requires considerable equipment to be located in an attic or elsewhere in the building in order to operate the system. The present invention overcomes the above and other drawbacks of the prior art by providing an improved integrated pest control system that utilizes equipment that can be easily installed and maintained, with little or no interruption in building construction scheduling and without the need for concealed moving parts or the requirement for cumbersome dispersing control machinery. SUMMARY OF THE INVENTION In accordance with one aspect of the present invention an integrated pesticide applicating system is provided which utilizes lengths of small diameter flexible plastic tubing formed with tiny discharge orifices at periodic intervals. The tubing is installed in wall voids, suspended ceilings and similar hollow spaces of buildings and has an end that terminates at a wall receptacle which serves as an access port for the injection of pesticide material. The tubing length and diameter, hole size, and pesticide application parameters are chosen to provide a predetermined approved measured amount of chemical coverage for the desired pest control coverage. A preferred system has tubing installed horizontally through the studs within every interior and exterior wall, and placed laterally at regular intervals within false ceiling spaces. Additionally, other installations are optionally made behind and under the fixtures, equipment, food pantries and applicances in food preparation areas; within the pony walls, booths and serving counters of dining areas; and behind and under the showers, tubs and cabinets in restroom facilities. A preferred spacing for discharge orifices is every 12" along suggested 40 to 60 foot lengths of tubing. The system is preferably serviced on a regular basis by a certified pest control technician who injects metered amounts of an expanding pesticide propellant into the port/receptacles. The perforations are advantageously shaped to converge conically outward so that the propellant can expand hundreds of times its original mass as it flows out the discharge orifices and completely fills the cracks, crevices, hollow spaces and voids where pests live, hide and breed. The system and method of application of the invention forms a "behind the scenes" network deep within a structure to maintain a building free and clear of pests. Timing of the pesticide injection ensures correct, approved application in predetermined amounts. The pesticide is contained within the wall cavities, thereby minimizing exposure to ultraviolet light and contact with people and animals or their immediate surroundings. In a preferred method of application, after injecting the pesticide, cleansing is performed by injecting an inert gas, such as nitrogen, into the tubing to expel chemical residue left in the system and to clear the orifices to prepare for the next injection. In an advantageous installation, described below, lengths of tubing establish pesticide distribution zones throughout the house and are terminalled at externally mounted injection receptacles which can be accessed by a pest control technician without the need for entry into the building itself. The simplicity of the tubing and the receptacle mounting arrangements provides for ease of installation, with little or no delay in construction schedules and with little requirement for maintenance. BRIEF DESCRIPTION OF THE DRAWINGS Embodiments of the invention have been chosen for purposes of illustration and description, and are shown in the accompanying drawings, wherein: FIG. 1 is a partially schematic view showing an installation and operation of a system in accordance with the invention; FIG. 2 shows installation of tubing and operation of the system of FIG. 1, in a wall of a building; FIG. 3 is an exploded view showing installation of a length of tubing to a single terminal receptacle; FIG. 4 is an exploded view of a multi-terminal receptacle; FIG. 5 is an enlarged fragmentary view showing the formation of apertures in the tubing; and FIG. 6 is an enlarged view showing a nozzle adapter for application of chemical in the system. Throughout the drawings, like elements are referred to by like numerals. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Implementation of the principles of the invention is illustrated in its application to embodiments of an integrated pesticide applicating system illustrated in FIGS. 1-6. With reference to FIGS. 1 and 2, preferably at the time of building construction, flexible conduit 11 is run horizontally 6 to 8 inches up from the base plate 12 through studs 14 of interior and exterior walls of a building and through other confined spaces, such as behind the partitions of built-in bookcases 15 and storage cabinets 16, 17. The conduit 11 is also run within false ceiling spaces 18 and, where applicable, throughout crawlways 19. The preferred conduit comprises small diameter polyethylene tubing (0.125 inch OD and 0.065 inch ID) installed in 40 to 60 foot lengths, terminating at exterior or interior port receptacles 20. The tubing (viz. 1/8 inch tubing) is run through the studs by drilling holes 21 (viz. 1/4 inch holes) horizontally through the studs parallel to the plane of the wall (FIG. 2). Similar passage is made through other structural members. The tubing 11 is preferably of the flexible, extruded type available commercially as, for example, from Union Carbide Linear Low-Density Polyethylene extrusion compound that exhibits good environmental stress cracking resistance and good extrusion characteristics. The tubing is advantageously also formed with a UV resistant material to maintain its flexibility prior to and throughout installation. The tubing 11 is provided with periodic apertures or perforations 22 which serve as outlet ports for the emission into concealed building areas of pesticide in a manner described below. The perforations 22 are preferably spaced every 12 inches, to ensure that at least one perforation 22 will be located in each wall void 24 for standard stud spacings of 16 or 24 inches center-to-center. Other spacings are, of course, possible. However greater spacings, e.g. every 15 inches, can lead to two perforations in one wall void 24 and no perforations in an adjacent wall void 24' (see FIG. 2). Smaller spacing, e.g. 6 inches or 8 inches, will give the desired at least one perforation per wall void but will result in a decrease in pressure along the tubing length for expulsion of the pesticide material. One end of each tubing length is closed, as shown in FIG. 3, the other open end is connected to a receptacle 20. This may be accomplished simply, as shown, utilizing conventionally available materials. The 1/8 inch diameter tubing can, for example, be doubled over to form the closed end 25 and a sleeve in the form of a short length of 1/4 inch standard drip irrigation tube 26 is then slipped over to secure the same. The other end 27 is then mounted in an accessible manner to receptacle 20. The end 27 may, for example, be brought into the serrated wall-inserted expanding end of a 1/4 inch plastic anchor 28 which is inserted coaxially into a standard 1/4 inch cable bushing 29 positioned within an opening 30 of a standard TV cable wall mounting plate 31. The interior portion of the bushing 29 is maintained in place by sliding a short length of 3/8 inch drip irrigation tubing 32 over the outside diameter of the bushing 29. The plate 31 is mounted after the (FIG. 1) wall is finished onto a standard electrical box 33 which, for external walls, can be provided with a 1/2 inch mud ring or other waterproofing mechanism 34 (FIG. 2). FIG. 3 shows a simple version of receptacle 20 for mounting the open end 27 of a single length of tubing 11. However, as illustrated in FIGS. 1 and 4, multiple terminal receptacles can also be provided. FIG. 1 shows the use of a plurality of zones of coverage, the open ends 27 of each tubing length 11 providing coverage in that zone terminating at a single receptacle 20. FIG. 4 shows the use of a special box for access from the exterior of a building to internally located tubing lengths by a certified pest control technician or other supplier of pesticide. As shown, a plurality of tubing lengths 11 terminate at anchors 28 mounted in openings of a plastic plate 35. The plate is dimensioned to snuggly fit within the protected recess of an outdoor electrical outlet box 36 with the lengths 11 passing through a central opening 38 therein. The box 36 includes a spring-loaded cover 37 which, when opened, permits access to the ends 27 of the several tube lengths 11 and, when closed, shields the same from the weather. The mounting of one or more boxes 36 on the building exterior permits injection of pesticide into various zones of coverage, without the need for the person applying the chemicals to gain entrance to the interior of the structure. A lock (not shown) may optionally be provided on the box 36 to prevent unauthorized use thereof. FIG. 5 illustrates the construction of the perforations 22 along the tubing 11. The same are preferably made in the outer wall of standard tubing in the form of conical-shaped apertures 22 that diverge outwardly at an approximately 25° pitch. For standard 1/8 inch OD polyethylene tubing, with an outside diameter of 0.125 inches and an inside diameter of 0.063 inches, the apertures 22 are formed with a 0.063 inch diameter inner opening and a 0.125 inch diameter outer opening, preferably using a diamond tipped razor blade 40 of triangular shape that contacts the tubing and rotates in a circle about a vertical axis to create a perforation 22 as the tubing is brought to a momentary halt after exiting from the extruder. The finished product is then rolled into thousand foot, or so, lengths onto rolls for subsequent cutting at the job site. As shown schematically in FIG. 1, once the tubing lengths 11 and receptacles 20 are installed for the various zones of coverage, the system can be serviced on a regular basis by a certified pest control technician who injects measured amounfts of a pesticide propellant into the exposed open ends 27 of the lengths 11 at the receptacles 22. The preferred propellant includes an expanding agent that permits it to be injected into the tubing and then expand as it leaves the perforations 22 (see the release of chemical depicted in FIG. 2). Suitable materials utilizable with the present system include conventional crack and crevice aerosols, foggers and injection chemicals, such as those available commercially from Whitmire Research Laboratories, St. Louis, MO, and marketed under the trade names PT 110™ Resmethrin aerosol generator; PT 565™ Pyrethrum insect fogger; PT 550™ Resmethrin insect fogger; PT 500™ Activated Pyrethrum insect fogger; PT 3-6-10™ Aero-Cide insect fogger; PT 280™ Orthene™ acephate insecticide; PT 270™ Dursban™ injection pesticide; PT 260™ Diazinon™ injection pesticide; and PT 250™ Baygon™ injection pesticide. The micro-encapsulated pesticide is propelled by use of a pressurized canister or similar EPA approved container 41 (FIG. 1) having a nipple 42 which fits within the exposed end 27 of a length of tubing 11 at a receptacle terminal 20. FIG. 6 shows a novel adapter fitting 43 having a hollow nipple stem 44 at one end that fits into tubing 11 and a threaded pipe 45 at the other end that mounts into the standard nozzle of a commercially prepackaged pressurized pesticide container. A central larger diameter knurled section 46 intermediate the two ends provides a gripping surface for hand attachment. Pesticide of a particular pressure is introduced into tubing 11 for a prespecified length of time to give the controlled amounft of discharge through the tubing 11 and out the perforations 22 (see FIG. 2) into the building concealed cavities. At 180 PSI, for example, a 7 second spray would be sufficient for a 40 to 60 foot length of tubing, with 25° conical perforations at 12 inch intervals, to dispense the required measured amount of pesticide expanding many, many times its volume. To extend greater distances from a particular receptacle while maintaining substantially the same pesticide release characteristics, lengths of unperforated tubing can be added to the ends of the perforated tubing lengths that connect to the receptacle. It has been satisfactorily demonstrated, for example, that 40 foot lengths of unperforated tubing can be connected to 40 to 60 foot lengths of perforated tubing without marked degradation of persticide release characteristics. The lengths of perforated and unperforated tubing may be connected, for example, using commercially available connectors for air and fluid lines in hospitals and such, like the LeGree 1/8 inch tubing connector. A preferred injection nozzle for use with the above-described freon based propellants is the Whitmire Tri-gun which includes connections for two chemical propellants and a selector for choosing expulsion of the first chemical only, the second chemical only, or both chemicals simultaneously. For the inventive system, the pesticide tank is connected into one chemical channel and the cleansing gas tank (i.e. nitrogen tank) is connected into the other channel. The two tanks are advantageously joined rigidly together for servicing convenience. This periodic insertion of pesticide at the receptacle terminals maintains a substantial control of pests within all wall cavities, while minimizing the deterioration of the chemicals due to exposure to ultra violet light and the risk of contact with people and animals or their immediate surroundings. After injecting the pesticide, a cleansing of the tubing is performed by injecting 10 seconds of nitrogen gas--eliminating all residue chemical left inside the tubing and preparing it for the next injection of chemical treatment. The apparatus and method of the present invention provides an improved integrated pest control system easily installed at the time of construction by a builder with no requirement for blueprint changes to be made. The only change in the production schedule is that the system installer is called at the time of electrical inspection, with most installations taking only a few hours. The flexible tubing is rapidly threaded through the building framework. No valve or other similar mechanisms need be installed. Such an installation is an attractive as a benefit for potential homebuyers. The invention permits measured amounts of EPA approved standard pesticides to be sprayed inside the walls and into otherwise inaccessible areas on a periodic basis to provide a lasting pest control barrier. Pre-prepared materials require no chemical mixing. There is better protection over conventional crack and crevice pest control application because bugs are reached where they hide. There is no ultra violet light inside the walls to dissipate the chemical residue, therefore less treatment is required for the same effect. The maintenance of chemicals inside the walls is preferred over contact treatment of exposed surfaces because of reduced hazard to children and pets. With outside service boxes, the homeowner need not be home to get inside pest control service. Because the chemicals stay within the walls there is less odor and there is no wall, baseboard, carpet, drapery or furniture staining. Running the tubing behind kitchen and bath cabinetry permits the application of chemicals to those areas without the need to empty shelves or closets. By treating areas normally used as accessways by the pests, transfer of pests from room to room and from exterior to interior walls is prevented. Those skilled in the art will appreciate that the preferred embodiments of the invention described above are just examples of how the invention can be implemented, and that various substitutions and modifications may be made therein without departing from the spirit and scope of the invention as defined by the claims below.
An integrated pesticide applicating system utilizes lengths of small diameter closed end flexible tubing with periodically spaced perforations having open ends terminating at junction boxes which are serviced on a periodic basis by certified pest control technicians utilizing expanding chemicals that are administered in measured quantities to provide a residual pest control block in concealed areas of a building. Externally mounted junction boxes provide a pest control method in which the chemicals can be applied without the necessity of access to the interior of the building by the servicing technician. Tubing perforations are preferably conically shaped.
4
BACKGROUND OF THE INVENTION [0001] I. Field of the Invention [0002] This invention relates generally to trailer jacks used to support the tongue of a trailer when the trailer is not coupled to a towing vehicle, and more particularly to a trailer jack allowing for rapid deployment. [0003] II. Description of the Prior Art [0004] A typical trailer jack is used to support the tongue weight of a trailer when the trailer hitch is not fastened to a towing vehicle and generally comprises an upper, outer tube adapted to be coupled to the trailer tongue and a lower inner tube coupled in telescoping relation to the upper outer tube and incorporating a lead screw member that is journaled for rotation in the upper, outer tube about a longitudinal axis thereof. The lead screw is threaded into a traveling nut that is welded to the inner wall of the lower, inner tube so that when the lead screw is rotated by a crank, the lower inner tube can be made to project further from or retract back into the lumen on the upper outer tube, depending on the direction of rotation of the crank. A disadvantage of this type of jack is that it takes many rotations of the crank to move the lower tube between a retracted disposition needed to provide ground clearance when the trailer is being towed and an extended disposition needed to elevate the trailer tongue when decoupling the trailer tongue receiver from the ball hitch of the towing vehicle. [0005] The Ryan U.S. Pat. No. 2,939,679 addresses this problem by providing a tension spring that is operatively coupled between the upper and lower tubes, allowing a user to step down on a footplate affixed to a bottom end of the lower tube to rapidly move the footplate against the ground and lock the lower tube in its extended position. At this point, only a few turns of the crank are needed to raise the trailer tongue sufficiently to uncouple the trailer from the towing vehicle. When it is desired to retract the lower tube into the upper one, when the lock is released, the tension spring works against gravity to lift the foot sufficiently to provide the needed ground clearance. Because the jack of the '679 patent comprises only two telescoping tubes, it is unduly long and cumbersome. [0006] The McMahan U.S. Pat. No. 8,091,922 teaches another way of obtaining a fast initial adjustment of the jack, followed by a final adjustment using a lead screw where the final adjustment makes it only necessary to make a few turns of the screw to achieve a desired elevation. The jack is comprised of an inner tubular member nested within an outer tubular member, a collar, a housing and a pin. The inner member is threadedly connected to the outer member with a bolt having a crank attached at one end. The bolt enables incremental adjustments in the trailer height by extension and refraction of the inner member with respect to the outer member. The connected outer and inner members are secured to the trailer with a pin inserted through the housing, a hole in the collar and one of a plurality of longitudinal holes in the outer member. To create rapid gross adjustment in the trailer height, the pin is retracted, a different hole in the outer member is registered with the hole in the collar and the pin is then reinserted. Having a plurality of longitudinally spaced holes in the outer member necessarily weakens the structural integrity of the jack. [0007] The Wilson U.S. Pat. No. 4,769,864 describes a trailer jack having a tubular outer housing adapted to be attached to a trailer vehicle with second and third tubular members slidably disposed therein. A locking mechanism is provided adjacent an aperture in a wall of the second tubular member for positioning a pin in selectively alignable apertures in a wall of the third tubular member, thereby preventing relative movement between the second and third tubular members. A tension spring engages both the second and third tubular members, the spring being located within the third tubular member. It functions to bias the third tubular member toward a retracted position with respect to the second tubular member. A crank is provided for rotating a threaded screw member for moving the second tubular member with respect to the tubular outer housing. [0008] The present invention is deemed to be an advancement over the prior art in affording an improved releasable locking arrangement that affords greater selectivity over the initial positioning of the lower tubular member with respect to the intermediate member. SUMMARY OF THE INVENTION [0009] The present invention comprises a trailer jack adapted for connection to a tongue of a trailer that comprises an upper tubular member of a predetermined cross-sectional shape, an intermediate tubular member of the same cross-sectional shape that is telescopingly received within the upper tubular member. A lower tubular member is telescopingly received within the intermediate tubular member and an elongate tension spring is disposed within the lower tubular member and operatively coupled for normally urging at least a portion of the lower tubular member into the intermediate tubular member. [0010] A swivel bracket is affixed to the exterior of the upper tubular member and is adapted to attach the trailer jack to the tongue of a trailer in a way that permits the jack to be rotated between a vertical and a horizontal orientation with respect to the trailer tongue. A threaded rod is journaled for rotation about a central longitudinal axis of the upper tubular member and cooperates with a traveling nut affixed to the interior of the intermediate tubular member such that rotation of the threaded rod by a hand crank displaces the upper tubular member with respect to the intermediate tubular member and the lower tubular member. [0011] A plurality of regularly, longitudinally-spaced detent holes are formed on an exterior wall of the lower tubular member. A latch is pivotally secured to a lower end portion of the intermediate tubular member and comprises a pin with a flat plate affixed intermediate its ends and that is normally urged by a compression spring into engagement with a selected one of the regularly longitudinally spaced holes on the lower tubular member for releasably locking the lower tubular member with respect to the intermediate tubular member. The latch further comprises a pedal plate positioned such that depression thereof against a force provided by the same compression spring for the pin disengages the pin from a selected one of the holes allowing the elongate tension spring to retract the lower tubular member into the intermediate one. For increased safety against inadvertent tripping of the jack's release, a locking pin can be inserted that cooperates with the flat plate to prevent movement of the spring-biased pin. [0012] The foregoing features, objects and advantages of the invention will become apparent to those skilled in the art from the following detailed description of a preferred embodiment, especially when considered in conjunction with the accompanying drawings in which like numerals in the several views refer to corresponding parts. DESCRIPTION OF THE DRAWINGS [0013] FIG. 1 is a rear elevation view of the trailer jack comprising a preferred embodiment of the present invention; [0014] FIG. 2 is a side elevation thereof; and [0015] FIG. 3 is a partial view showing the spring biased detent employed. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0016] This description of the preferred embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. In the description, relative terms such as “lower”, “upper”, “horizontal”, “vertical”, “above”, “below”, “up”, “down”, “top” and “bottom” as well as derivatives thereof (e.g., “horizontally”, “downwardly”, “upwardly”, etc.) should be construed to refer to the orientation as then described or as shown in the drawings under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as “connected”, “connecting”, “attached”, “attaching”, “join” and “joining” are used interchangeably and refer to one structure or surface being secured to another structure or surface or integrally fabricated in one piece, unless expressively described otherwise. [0017] As seen in FIG. 1 , the trailer jack 10 comprises three telescoping segments, namely, an upper, outer tubular member 12 of rectangular cross-section, an intermediate tubular member 14 also of rectangular cross-section but having an outer dimension capable of being slidingly fit within the lumen of the upper, outer tubular member 12 . Fitting telescopically into the central lumen of the intermediate tubular member 14 is a lower tubular member 16 at the lower end of which is secured a footplate 18 . The footplate 18 has a rectangular collar 20 dimensioned to fit about the lower end of the lower tubular member 16 . A bolt 22 passes through aligned apertures in the collar 20 and the lower tubular member 16 as a mode of attachment. [0018] Welded to the upper tubular member 12 is a swivel mounting bracket assembly indicated generally by numeral 24 . It comprises a base member 26 having arms, as at 28 , 30 , that straddle and are welded to opposed side surfaces of the upper, outer tubular member 12 and secured to the base member 26 is a swivel plate 34 . The swivel plate 34 has a cylindrical sleeve 35 ( FIG. 2 ) rotatably secured in a circular aperture 32 in the base member 26 . A wire ring retainer 33 prevents uncoupling of the sleeve 35 from the base member 36 . [0019] The swivel plate 34 is adapted to be connected to a trailer tongue by suitable fasteners, such as bolts 37 that pass through clamping bars 39 . The jack mounting bracket assembly 24 thus permits the jack to be swung between a vertical disposition when supporting the trailer tongue to a horizontal position when the trailer is being towed. A U-shaped handle 41 extends through the arms 28 and 30 of the mounting bracket 26 and a pair of compression springs 43 surround portions of the legs of the U-shaped handle 41 and apply a biasing force urging end portions of the U-shaped handle through aligned apertures in the base portion of the mounting bracket and the swivel plate 34 . This serves to releasably lock the jack assembly in either a horizontal disposition with respect to the tongue of a trailer or in a vertical disposition depending upon which of the aperture pairs on the swivel plate 34 (A-A or A-B) are brought into alignment with the legs of the U-shaped handle 41 . [0020] As can be seen in the partial, cut-away view of FIG. 2 , journaled for rotation in a bearing 36 mounted close to the top of the jack is a threaded lead screw 40 that is threaded through a traveling nut 42 welded to the inside wall of the intermediate tubular member 14 . Thus, by turning the crank 44 that is joined to the upper end of the lead screw 40 by a bevel gear connection 38 , the lead screw 40 is rotated, causing the intermediate tubular member 14 to be drawn into the lumen of the upper, outer tubular member 12 or moved outward so as to project further out from the lower end of the upper tubular member 12 , depending upon the direction of rotation of the crank 44 . [0021] Contained within the lumen of the lower tubular member 16 is a tension spring 48 whose lower end is hooked about the bolt 22 used to fasten the foot member 18 to the lower end of the tubular member 16 . The spring extends upward through the lumen of the lower tubular member 16 and hooks about a pin 50 that extends transversely through opposed side walls of the intermediate tubular member 14 . Thus, the spring 48 normally tries to retract the lower tubular member 16 into the intermediate member 14 . A cable 49 is also connected between the bolts 22 and 50 whose length prevents the lower tubular member 16 from coming free of the lumen of the intermediate tubular member 14 . [0022] As seen in the partial detail view of FIGS. 1 and 3 , there is formed in one side surface of the lower tubular member 16 a series of longitudinally spaced holes 52 that are spaced apart approximately ½ inch although this spacing is not critical and can be as small as ¼inch and as large as ¾inch. The holes 52 thus form a detent surface along the length dimension of the lower tubular member 16 that is made to cooperate with a spring-loaded pin 54 . More particularly, welded or otherwise affixed to an outer wall of the intermediate tubular member 14 proximate its lower end is a block-like housing 56 in which is disposed a spring biased pin, the end of which can best be seen in FIG. 3 . Pivotally joined to the housing 56 is a pedal member 58 that pivotally joins to the housing 56 by means of a hinge pin 60 . The pedal member 58 has opposed arms 62 that straddle the lower end portion of the intermediate tubular member 14 and the pin 54 is operatively coupled to the ends of the arms 62 . More particularly, an angled plate 63 is welded to the opposed arms and a rear end portion thereof wraps down over the housing 56 . The portion of the angled plate 63 that wraps down is identified by the numeral 65 and as seen in FIG. 1 , it includes a U-shaped cutout 67 through which a rear end of the pin 54 extends. A roll pin 69 extends through the pin 54 and its length is such that it extends beyond the opposed side edges of the cutout 67 . It can be seen then that downward depression of the pedal member 58 pivots the pedal arms about the hinge pin 60 and in doing so forces the pin 54 rearward against the force of its biasing spring 71 to the point where the pin 54 no longer engages one of the holes 52 . [0023] With continued reference to FIG. 3 , there can be observed a steel plate 72 affixed to the pin 54 intermediate its ends and with compression spring 71 pressing on it. A locking bolt, as at 74 , when inserted through aligned apertures in the housing 56 , abuts the plate 72 to block the ability of the pin 54 to move, thus providing a safety feature preventing inadvertent release of the jack. [0024] Having described the constructional features of the jack of the present invention, consideration will next be given to its mode of operation. [0025] Let it be assumed that the trailer had been traveling over the road and has arrived at a spot where the trailer is to be parked. At this point, the longitudinal axis of the jack will be generally horizontal and aligned with the tongue of the trailer. The lower tubular member 16 will be retracted within the intermediate tubular member 14 under action of the tension spring 48 . The operator will first pull the U-shaped handle 41 that secures the jack in its horizontal disposition and will rotate the jack about the cylindrical swivel 32 that connects the base member 26 to the swivel plate 34 , the swivel plate 34 being joined to the tongue of the trailer. Next, by placing one's foot on the plate 18 and stepping down, the lower tubular member 16 will be displaced outward from the lower end of the intermediate tubular member 14 against the force of the tension spring 48 . The pin 54 will click through the holes 52 and will ultimately stop in one of the holes determined by the length of travel of the lower tubular member needed before the footpad 18 abuts the ground. The operator may now insert the safety locking bolt 74 to prevent release of the lower tubular member from its engagement with the intermediate tubular member and turn the crank 44 only a few turns in a direction that will elevate the trailer tongue by displacing the intermediate tubular member from the lumen of the upper, outer tubular member 12 . This decouples the trailer's hitch receiver from the ball hitch on the towing vehicle. [0026] Later, when it is desired to again transport the trailer, the operator will maneuver the towing vehicle so that a hitch ball on the towing vehicle will be positioned directly beneath the hitch ball receiver on the end of the trailer tongue and then the crank 44 may again be rotated only a few times in a direction to lower the trailer tongue so that the receiver will engage the hitch ball. Now, by simply removing the locking bolt 74 so that it no longer prevents movement of the plate 72 and the spring-biased pin 54 and then stepping on the pedal 58 or otherwise pushing it down, the spring-biased pin 54 will become disengaged from the hole 52 in which it resided, allowing the tension spring 48 to rapidly draw the lower tubular member 16 into the intermediate tubular member 14 to thereby provide sufficient ground clearance to permit over-the-road travel. If it is contemplated that the trailer is to be taken off-road, additional ground clearance can be achieved by again rotating the jack about the swivel 32 so that the longitudinal axis of the jack will again be horizontally disposed alongside the trailer's tongue. [0027] This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself.
A fast-adjust trailer jack has three telescoping tubular segments, an upper, an intermediate and a lower. A lead screw is used to operatively couple the upper to the intermediate and a tension spring is coupled between the intermediate and the lower to normally urge the retraction of the lower into the intermediate. A spring-biased pin and hole based detent mechanism is employed to allow setting of the degree of extension of the lower tubular segment with respect to the intermediate tubular segment.
1
[0001] Device for levelling and aligning surface covering parts. OBJECT OF THE INVENTION [0002] This invention relates to a device for levelling and aligning surface covering parts, appropriate to install a surface of ceramic parts or similar that are suitably levelled and aligned. FIELD OF APPLICATION OF THE INVENTION [0003] The invention is applicable in the field of construction and refurbishment, particularly in the application of surface covering tiles or parts. BACKGROUND OF THE INVENTION [0004] There currently exist in the market different devices designed to facilitate the levelling and alignment of surface covering parts using a layer of mortar, glue cement or other suitable adhesive for securing them to the surface in question. [0005] The purpose of these known devices is to facilitate the correct positioning of the parts forming the covering, so that the covering defines a flat, levelled surface, and the parts in question are kept at uniform distance apart. [0006] A known device is described in the U.S. Pat. No. 4,397,125, which has a rear plate with a hole in which a screw or protruding tab is fixed directly with fixing means to said screw. Said device also has a front clamping plate mounted on it, which is forced against the rear plate by a wing nut or similar, in order to trap the covering parts by their edges. The device in this patent has a number of drawbacks, notably that the threaded parts of the screw and/or wing nut may be rendered useless if they come into contact with the mortar or fixing material for the covering parts, and the excessively large separation between said parts because of the thickness of the screw, especially when the parts to be used are of small dimensions. [0007] The document U.S. Pat. No. 5,675,942 describes an aligning and spacing device for wall panels which comprises a base plate with an attachment or locking stem, locking plate and lock which keep the front and rear sides of a pair of panels laterally aligned with a surface while the securing product for said panels dries. [0008] The lock incorporated in the locking plate is coupled to the stem using complementary gear teeth of sizeable dimensions, which means that there is an excessive length between the successive holding points and that the alignment and levelling of the parts forming the covering is not sufficiently precise. [0009] Other known devices are described, for example, in patent documents US 2006/0185269 and US 2006/0185319, which have a top plate with an array of spacer fins and a bottom plate, in which the plates are joined by a stem or attachment which extends from the bottom plate through the top plate. This stem has a number of notches for lateral mounting of a metal insert to hold the top plate in position. [0010] As in the previous case, these inventions do not allow progressive insertion and appropriate adjustment of the top plate during the levelling of the parts which form the covering. [0011] The Spanish utility model ES 1070518 U describes a levelling device for the positioning of covering parts which comprises a flat lower body from which a flexible attachment emerges from above for placing between the covering parts and a second upper body with a through hole for adjustable mounting on the flexible attachment. Said flexible attachment has a rectangular cross-section and, on its larger faces, two opposing gear teeth whose teeth are offset lengthwise. The through hole of the second body comprises two opposing ratchets which mesh in an alternate manner with the teeth corresponding to the two sides of the flexible attachment, providing a greater number of fixing points than in the abovementioned inventions. [0012] This invention, like the previous ones, has the disadvantage that each device is positioned individually, which makes alignment and levelling of covering parts difficult, especially when they are of longer length. Another drawback in use comes from the fact that a large number of individual, independent devices must be used for the alignment and levelling of the covering parts. [0013] Another drawback of this device is determined precisely by the flat configuration of the lower body, which prevents the covering parts from being gripped correctly in the cement or fixing medium with regard to the surface to be covered. DESCRIPTION OF THE INVENTION [0014] This invention describes a device for levelling and aligning surface covering parts, which device that can be used to install a surface of ceramic parts or similar that are suitably levelled and aligned, using a securing product. [0015] The device comprises a base and flexible attachments with their respective upper bodies. The attachments protrude from the top of the base and have lateral gear teeth. The upper bodies are suitable for pressing onto the upper surface of the covering parts. The upper bodies have a through hole so that they can be mounted in sliding fashion on the flexible attachments, towards the base. For this purpose, they have internal gear teeth designed to act against the gear teeth incorporated in the flexible attachments, holding the upper body in an operating position against the covering parts. [0016] The device comprises a base with an undulated surface, creating a series of alternating troughs and peaks along its length, which are suitable for the penetration of the securing product for the covering parts. [0017] The device also comprises at least two flexible planar attachments, which protrude from the top of the base, and are arranged to correspond with a longitudinal middle plane on the base, separated along its length, in which each of the flexible attachments has on the opposing planar surfaces: side ribs for guiding and sliding assembly of the two upper tightening bodies on the upper surface of the covering parts, and central gear teeth which are suitable for the action of complementary teeth on the respective upper bodies. [0018] The device comprises between the successive flexible attachments a crosswise weakening line, suitable for the separation of the base into independent segments, each of which has a corresponding flexible attachment. The device has a base with a rectangular plane and a structure which may be longitudinal, formed of at least two segments joined along their length; or in the form of an orthogonal cross formed by four arms. [0019] The cross-shaped base comprises a rectangular promontory located in the geometrical centre and oriented according to two of the arms of the cross. One of the arms of the cross-shaped base comprises, on its non-free end, a crosswise weakening line which extends the two adjacent arms, suitable for separating the arm from the rest of the base, giving it a T-shaped structure. [0020] Each of the segments of the bases or the arms of the base with a cross-shaped structure comprises a projection with a rectangular drill-hole positioned to coincide with the base, which forms a hollow in the opposite side of the base and copies the structure of the projection to maintain the thickness of the base. [0021] The projections have a rectangular structure with curved shorter sides and longer sides parallel to the rectangular drill-hole and, consequently, to the longer sides of the base or the arms of the base, if it is cross-shaped. [0022] The independent flexible attachment comprises a support which fits in the hollow of the projection when inserted through the drill-hole in the projection. [0023] The non-free end of the flexible attachments has holes which define an area of weakening suitable for breaking. [0024] When large size parts are used, the bases comprise lines of drill-holes or perforations located crosswise at each side of the rectangular drill-holes. These drill-holes allow the device to be submerged easily in the cement or joining element for the parts, so that it flows through the perforations. DESCRIPTION OF THE FIGURES [0025] To complement the description being made, and to make it easier to understand the characteristics of the invention, this descriptive report is accompanied by a set of drawings in which, for illustrative purposes and without limitations, the following has been represented: [0026] FIG. 1 shows an elevation view of the device of the invention in a first example of embodiment, which shows the base and two flexible attachments with their corresponding upper bodies and an enlargement of the area of weakening at the base of the flexible attachments. [0027] FIG. 2 shows a top plane view of the device in the previous figure. [0028] FIG. 3 shows a low plane view of the device in the previous figures. [0029] FIG. 4 shows a view of the A-A′ section marked in FIG. 1 , showing an enlargement of the gear-teeth area for coupling the upper body to the flexible attachment. [0030] FIG. 5 shows a higher perspective view of the device in the invention in a second embodiment with a longitudinal base. [0031] FIG. 6 shows a exploded perspective view of the device in the invention as represented in FIG. 5 . [0032] FIG. 7 shows an underside view of the device in the invention shown in FIGS. 5 and 6 . [0033] FIG. 8 shows a low plane view of the device represented in FIGS. 5 to 7 . [0034] FIG. 9 shows an elevation view of the device represented in the previous figure [0035] FIG. 10 shows a top plane view of the device represented in the previous figure. [0036] FIG. 11 shows a perspective view of the independent flexible attachment with an enlargement of the foot in the second embodiment. [0037] FIG. 12 shows a perspective view of the device in the second embodiment with an extended longitudinal base. [0038] FIG. 13 shows an explored perspective view of an embodiment of the cross-shaped base. [0039] FIG. 14 represents a top plane view of the device in the second embodiment with a cross-shaped base. [0040] FIG. 15 shows an elevation view of the device represented in the previous figure. [0041] FIG. 16 shows a form of representation of the device with extruded base for use with large size parts. [0042] FIG. 17 shows a surface covered with tiles configured in staggered formation using the device in the invention. [0043] FIG. 18 shows a surface covered with tiles aligned using the device in the invention. [0044] Provided below is a list of the references used in the figures: [0000]  1. First base.     1′. Second base.  1″. Third base.  2. Incorporated flexible attachment.     2′. Independent flexible attachment.  3. Upper body.  4. Support for the independent flexible attachment.  5. Projection.  6. Rectangular drill-hole.  7. Rectangular promontory.  8. Ends of the base.  9. Undulated structure of the base. 10. Hollow in the projection. 11. Troughs in the undulated surface. 12. Peaks in the undulated surface. 13. Undulated profile. 14. Weakening line. 15. Arm of the cross-shaped base. 16. Separable base segment. 17. Perforations. 21. Side ribs. 22. Central gear teeth. 23. Holes. 31. Through hole. 32. Gear tooth. P. Covering parts. PREFERRED EMBODIMENT OF THE INVENTION [0045] The device in the invention has preferably three forms of embodiment, differentiated basically in the structure of the bases ( 1 , 1 ′) and in the way the flexible attachments ( 2 , 2 ′) are attached to the bases ( 1 , 1 ′). [0046] In a first embodiment, and as can be seen in the attached FIGS. 1 to 4 , the device in the invention comprises a first rectangular base ( 1 ) with a longitudinal structure. [0047] In a second embodiment, and as presented in FIGS. 5 to 15 , the device in the invention comprises a second base ( 1 ′). This second base ( 1 ′) is rectangular with a longitudinal structure or with a structure in the form of an orthogonal cross, in which the base ( 1 ′) has two or four ends ( 8 ), respectively. [0048] The bases ( 1 , 1 ′) have a longitudinal section with an undulated structure ( 9 ) which defines a series of troughs ( 11 ) and peaks ( 12 ) alternating along its length. In addition, the rectangular form of the longitudinal bases ( 1 , 1 ′) and of the arms ( 15 ) of the cross-shaped base ( 1 ′) has an undulated configuration ( 13 ) on the longer sides, as represented, amongst others, in FIGS. 2 and 3 . [0049] The bases ( 1 , 1 ′) incorporate at least two flexible planar attachments ( 2 , 2 ′), arranged to coincide with a longitudinal middle plane on the bases ( 1 , 1 ′). The flexible attachments ( 2 , 2 ′) are arranged symmetrically on the bases ( 1 , 1 ′) along their length, with two of these attachments close to the ends ( 8 ) of the bases ( 1 , 1 ′). In this way, bases ( 1 , 1 ′) with just two attachments ( 2 , 2 ′) can be found in the two forms of embodiment described. However, the second embodiment allows the incorporation of three flexible attachments ( 2 ′), as represented in FIG. 12 . [0050] The flexible attachments ( 2 ) in the first embodiment are fixed to the base ( 1 ) to form a single part. [0051] The flexible attachments ( 2 ′) in the second embodiment are independent and fixed to the base ( 1 ′) by pressure. [0052] In the second embodiment, the second base ( 1 ′) has, in the areas where the attachments ( 2 ′) are located, strengthening projections ( 5 ) of a height which does not exceed the troughs ( 11 ) of the undulated structure ( 9 ) of the base ( 1 ′). This detail is represented in FIGS. 9 and 15 . [0053] The projections ( 5 ) in the second embodiment have a circular structure with the perimeter cut by two diametrically symmetrical lines, creating a rectangular shape with circular shorter sides, oriented in the longitudinal direction of the segments ( 16 ) of the base ( 1 ′) or of the arms ( 15 ) if the base ( 1 ′) has a cross-shaped structure. [0054] The projections ( 5 ) have a hollow ( 10 ) on the opposite side of the base ( 1 ′) which copies the structure of the projection ( 5 ), so that the thickness of the base ( 1 ′) is roughly maintained. [0055] The projections ( 5 ) incorporate a rectangular drill-hole ( 6 ) passing through, which are geometrically aligned with the segments ( 16 ) of the base ( 1 ′) or with the arms ( 15 ) if the base ( 1 ′) has a cross-shaped structure. [0056] The independent flexible attachments ( 2 ′) in the second embodiment are identical to the flexible attachments ( 2 ) incorporated and fixed to the device, with the only difference being that they are separated from the base ( 1 ) in which they were incorporated as described for the first embodiment, and including a support ( 4 ) with a structure which copies the structure of the hollow ( 10 ) in the projections ( 5 ). In this way, the independent flexible attachments ( 2 ′) are inserted through the rectangular drill-holes ( 6 ) until the support ( 4 ) for the independent attachments ( 2 ′) is attached in the hollow ( 10 ) of the projection ( 5 ). [0057] It should be noted that the dimensions of the rectangular drill-holes ( 6 ) are greater than the dimensions of the section of the flexible attachments ( 2 ′) which pass through the drill-holes ( 6 ) so that, when inserted into them, the flexible attachments ( 2 ′) have a certain amount of play and are not aligned with the base ( 1 ′). When the support ( 4 ) which adjusts in the hollow ( 10 ) of the projection ( 5 ) is included, the position is fully defined. [0058] Another characteristic of the bases ( 1 , 1 ′) is that they comprise crosswise weakening lines ( 14 ) for the separation or splitting of the base ( 1 , 1 ′) into independent segments ( 16 ). These weakening lines ( 14 ) are halfway between every two projections ( 5 ) in the case of bases ( 1 , 1 ′) with a longitudinal structure. In the case of bases ( 1 ′) with an orthogonal cross-shaped structure, the weakening line ( 14 ) is a continuation of the longitudinal structure of the adjacent arms ( 15 ). In this way, if one arm ( 15 ) is eliminated, a segment ( 16 ) separated from the base ( 1 ′) is obtained, together with a T-shaped base ( 1 ′) with a structure with no protruding areas. [0059] In this way, considering the first embodiment, the segments ( 16 ) separated from the base ( 1 ) have the corresponding flexible attachment ( 2 ) so that it can be positioned individually, if it is not possible to use the full structure of the device because of problems of space. [0060] In the base ( 1 ′) with a longitudinal structure, various independent segments ( 16 ) can also be obtained, with as many independent segments ( 16 ) as there are projections ( 5 ) in the base ( 1 ′), to be used as bases ( 1 ′) in situations where there are problems of space. [0061] The base ( 1 ′) with an orthogonal cross-shape structure also has, in the geometrical centre and positioned in the direction of one of the arms ( 15 ), a rectangular promontory ( 7 ) which is used to ensure that the separation of the covering parts (P) to be positioned is exactly the same along the whole length of the flooring to be covered. A crosspiece like those known in the state of the art can be mounted on this rectangular promontory ( 7 ), although it does not form part of this invention. [0062] In a third embodiment, the device has more than three flexible attachments ( 2 ′). The base ( 1 ″) is formed of a surface with an undulated structure ( 9 ) which comprises a series of perforations ( 17 ) positioned crosswise to the base ( 1 ″) on both sides of each rectangular drill-hole ( 6 ).The perforations ( 17 ) facilitate the penetration of the cement or fixing medium for the covering parts (P) and the levelling thereof when pressed from above by the upper bodies ( 3 ) of the device. The base ( 1 ″) in this embodiment has a surface with an undulated structure ( 9 ) in a perpendicular direction to that used in the previous embodiments, so that it can be manufactured by extrusion. Both the rectangular drill-holes ( 6 ) and the perforations ( 17 ) are created at a later stage of manufacture. An example is shown in FIG. 16 , which is especially suitable for situations in which covering parts (P) of a large size are used, for example parts measuring 2 m by 1 m. [0063] In all the embodiments, the device comprises upper bodies ( 3 ) provided with a through hole ( 31 ) for sliding assembly on the respective flexible attachments ( 2 , 2 ′) towards the base ( 1 , 1 ′, 1 ″). [0064] As can be seen in the figures, the flexible attachments ( 2 , 2 ′) each have two opposing planar surfaces with side ribs ( 21 ) for guiding the respective upper bodies ( 3 ), and central gear teeth ( 22 ), with the teeth at the same height, as represented in the expanded detail in FIG. 4 . [0065] For their part, the upper bodies ( 3 ) designed to be mounted on the respective flexible attachments ( 2 , 2 ′) have in the through hole ( 31 ) two gear teeth ( 32 ) at offset heights, at a distance approximately equal to half the length of the teeth, as shown in the detail of FIG. 4 , so that they fix alternately the upper body ( 3 ) on the central gear teeth ( 22 ) of the opposing planar surfaces of the corresponding flexible attachment ( 2 , 2 ′). [0066] As can be seen in the detail shown in FIGS. 1 and 11 , the flexible attachments ( 2 , 2 ′) have at their lower end holes ( 23 ) which define a weakening area suitable for separating them from the base ( 1 , 1 ′, 1 ″). [0067] As can be seen in FIGS. 17 and 18 , the incorporation in a same device of several flexible attachments ( 2 , 2 ′) allows the correct alignment of consecutive covering parts (P), supporting each of the upper bodies ( 3 ) on said consecutive parts (P), given that the flexible attachments ( 2 , 2 ′) of each device are already aligned longitudinally. [0068] Once the covering parts (P) have been installed and the cement or fixing medium for the parts has set, the flexible attachments ( 2 , 2 ′) are stretched until they break at the point where they meet the base ( 1 , 1 ′, 1 ″), this base ( 1 , 1 ′, 1 ″) thus conforming a residual component which remains embedded under the covering parts (P). [0069] It should be noted that the improvement introduced by the second embodiment is substantial in terms of transport and manufacturing costs. [0070] In terms of transport, because all the parts can be disassembled, they can be stacked to occupy a minimum amount of space. [0071] In terms of manufacture, it should be noted not only that there is a radical reduction in manufacturing costs for the plastic parts, where the dimensions and complexity of an injection mould would considerably increase the cost of parts and the initial investment, but also in terms of the possibility of making the different components in different materials, selecting the most appropriate material for each requirement, with no need to use a single material for all the parts. This also means that the same component in the device can be made in different colours, to distinguish between them for any application, such as marking the first units used in an assembly. [0072] Having described sufficiently the nature of the invention, and the examples of preferred embodiment, it can be stated for the relevant effects that the materials, shape, size and arrangement of the elements described may be modified, provided this does not mean an alteration in the essential characteristics of the invention for which the claims are set out below.
The invention relates to a device for levelling and aligning surface covering parts in the installation of a surface of ceramic parts that are levelled and aligned using a securing product. The device comprises: a base ( 1,1′,1 ″) having an undulating surface; and at least two flexible planar attachments ( 2, 2 ′) projecting up from the base ( 1,1′,1 ″) and positioned symmetrically along the length of the base ( 1,1′,1 ″), the opposing planar surfaces of each of the flexible attachments ( 2, 2 ′) comprising side ribs ( 21 ) for slidably mounting and guiding upper bodies ( 3 ) which, by applying pressure, contact with the upper surface of multiple covering parts (P), thereby being levelled.
4
CROSS REFERENCE TO RELATED APPLICATIONS The present application is a 35 U.S.C. §371 National Phase conversion of PCT/ES2010/070096, filed Feb. 22, 2010, the disclosure of which is incorporated herein by reference. The PCT application was published in the Spanish language. TECHNICAL FIELD As expressed in the title of this specification, the present invention relates to a method for transcoding and playing back video files based on distributed computing network (GRID) technology in devices having limited computing power making use of the computing and distributed storage capacities offered by GRID platforms in the devices, such that said devices are capable of playing back any type of digital video file. To that end, the GRID will be responsible for running a transcoding application when necessary in order to transcode the original video file. This task will be carried out in a manner which is transparent to the user in one of the computing resources available in the GRID. Likewise, the video file to be played back can be located in the GRID user file system or can be external to the terminal, but accessible as if it were local as long as the terminal maintains the connection with the network. This invention also allows the video file to be provided by an external multimedia content provider. The link between the application and the GRID is possible as a result of the existence of middleware installed in the operating system of the terminal, therefore turning it into a general purpose application based on the GRID system for converting video and playing it back. The fields of application of this invention are distributed computing as well as multimedia content playback. BACKGROUND ART There are two starting points to approach this invention. On one hand, the increase in the number of mobile devices (and other multimedia devices having limited computing power) capable of playing back multimedia contents, and on the other hand, the already existing distributed computing network (known as GRIDs). Focusing on the first point, new mobile devices (smartphones, PDAs, etc.) are increasingly designed with displays having greater resolution and better video playback performance. However, there is a trend of recording very high resolution videos (even in high definition) or using compressed formats requiring a significant processing capacity in order to achieve a smooth playback and strongly limiting the video playback possibilities offered by current devices. For example, there are few mobile telephones which support the DivX codec, one of the most widespread on the Internet for video distribution. As a result, the content providers or the users themselves are forced to convert the content to enable playing it back on their terminals. To that end, there are several options, but generally some hardware and an application external to the terminal is needed such as: The user can use a local DLNA server with direct access to the video file source for carrying out the conversion, while the DLNA client application which must be run in the terminal receives and plays back the content. The content provider itself could be responsible for converting the original video for generating a converted copy suitable for the specific needs of the user terminal. In this line of creating copies of content, the provider or the user could use a web service exclusively intended for conversion provided by a third party. This third party could in turn use the infrastructures supplied by a cloud computing provider, such as Amazon EC2, for example, in order to perform costly video conversions. However, this option is more content provider orientated and, in any case, the original file must be sent to the third party, the converted video being recovered later on. This process consumes a large bandwidth and having this bandwidth is not always possible for the end users. Changing the focus towards distributed computing networks, the GRID platforms have been mainly used for intensive computing tasks (complex scientific calculations for industrial simulations). However, until the arrival of cloud computing, there were not many commercial initiatives offering computing capacities for the end users from their own devices. Today there are products such as Amazon® EC2 or Google® App Engine which allow contracting a specific amount of remote computing power. On the other hand, the XtreemOS project financed by the European Commission under the 6 th Framework Programme allows easy and harmonious integration with the GRID platforms. In fact, one of the specific research lines of XtreemOS focuses on accessing the GRID platforms from mobile devices, offering the end users the capacities offered by GRID computing. The present invention thus focuses on exploiting the native capacities of GRID platforms from devices with a limited computing power in order to transcode video in the GRID, taking into account that those tasks related to video conversion (format, resolution, etc.) require high computing power not usually available on the user terminals such as mobile telephones, PDAs, etc. Converting average or high quality videos using codecs such as DivX, Xvid or H.264 is a high consumption process in terms of processing, memory and storage space. Many devices with limited computing power (such as mobile telephones, PDAs, portable multimedia devices, etc.) are not intended for carrying out this conversion either because they do not have enough capacity or the time necessary for the conversion is too long, or even because the battery consumption would be excessive for such terminals. Given that the computing capacity of the equipment continues to grow year after year, it is difficult to quantify what is understood by limited computing capacity, but it can be considered that the computing capacity is limited when the equipment in question is capable of performing a number of instructions per second which is at least one order of magnitude below what a mid-range personal computer would be capable of performing. For example, currently a mid-range PC tends to be equipped with Core 2 Duo processors, with a performance of the order of tens of thousands of MIPS (millions of instructions per second). In turn, a current mobile terminal, such as the Nokia® N800 Tablet PC for example, is equipped with a processor from the ARM11 family with a processing capacity less than one thousand MIPS. On the other hand, many of those devices are equipped with some type of data interface, such as Wi-Fi or 3G, and have relatively advanced operating systems installed. Furthermore, they incorporate some video play back applications and video codecs which are run directly in the terminal itself. The video source can be local or is downloaded and played back from an external source by means of streaming techniques. But in any case, the playback is only possible if the video is coded with one of the codecs supported by the terminal. If not, the video must be transcoded into a suitable format if the terminal has an application specifically designed to that end, but even in this case, carrying out the transcoding in the same terminal would not be advisable given the following situations: i) the video source is not local, ii) the user does not want to consume the limited resources of its terminal. Other solutions based on Web services provided by third parties (such as the online video file conversion service, flixcloud, for example,) attempt the prior installation of the conversion application in the Web server and use a Web interface which will not always be the native interface of the operating system of the terminal, forcing the applications of the terminal to be modified. Modifying the application would be less complex or would not even be necessary with a solution based on middleware with GRID capacities. SUMMARY The present invention proposes a solution for this limitation by means of running a transcoding application in a grid computing platform. Furthermore, the platform will offer storage space for the user (making use of the distributed storage capacity of the GRID platform and its own security mechanism) where both the original video and the converted video will be stored. The solution also provides the terminal with middleware with GRID capacities in order to achieve complete grid integration. That means that the transcoding application could either be run directly in the terminal or in the GRID. Two different application scenarios of the present invention are distinguished. In scenario 1, the original video file is previously stored in the GRID distributed file system, the user being able to access it as if it were a local file of his/her device. This is possible as a result of the native running of a GRID file system in the user terminal. In scenario 2, the video file is sent to the GRID through an external content provider, such that in this case the user does not have direct access to the original video file. The method solving both scenarios comprises the following steps: 1. The client part of the multimedia transcoder/player selects a video file to be played back. A user interface is provided to that end. In scenario 1, the file is stored in a file system provided by the GRID, where the user has access similar to that of a local file. Then, the user will only have to select the file to be played back. In scenario 2, where the user does not have direct access to the file, the user will indicate its location by a Uniform Resource Locator, URL. In both cases, the user must be previously registered in the network, such that there will be a secure communication mechanism between the network and the user terminal, based on the specific integrity and security mechanisms of the GRID. Furthermore, in both cases, the client part of the multimedia transcoder/player will provide the user with the possibility of selecting the desired quality for converting video which will be played back from among the possible codec and resolution options supported by the terminal. There will be a default option and it will generally be the optimum option in terms of playback quality for the given terminal. 2. The multimedia transcoding/play back application will use the capacities to run processes in the GRID offered by the GRID middleware of the terminal. The client part of the multimedia transcoder/player will thus send a video conversion process to the GRID. When said process is run in the GRID the access path to the application responsible for the transcoding as well as the access path to the local file source (scenario 1) or the URL address of the remote file (scenario 2) and the necessary parameters will be indicated depending on the playback quality selected in the prior step. Once the transcoding task is started in any of the computing resources of the GRID, in scenario 1, the existence of a file in the selected path will be verified, whereas in scenario 2 the downloading of the file indicated by means of the URL and its storage in the GRID file system will start. 3. The specific transcoding part of the process sent to the GRID will be run according to the quality parameters desired and specified in step 1. In scenario 1, running the process will generate a transcoded video file which will be stored in the GRID user file system, to which the user will have access. Once the storing of the converted video ended and the GRID connector module detected the end of the process, an end of process notification is sent to the client part of the multimedia transcoder/player and from that moment the application of the client will be able to play back said transcoded video file. In scenario 2, since the video is being transcoded in the GRID it will be sent to the terminal by means of conventional streaming techniques such that the video can be played back at the same time that it is transcoded. The object of the invention which is a method and a system for transcoding and playing back video files based on GRID technology in devices having limited computing power can thus be defined in a more detailed manner. A multimedia transcoding/play back application and GRID middleware integrated in the user device will be previously provided. Said method is characterised in that it comprises the following phases: providing the device with a user interface for selecting a video file through the transcoding/play back application; verifying that the user is registered in the GRID by means of the GRID middleware and establishing a secure communication mechanism between said user and the GRID through integrity and security means integrated in the GRID itself; the user selecting the video file which must be played back; the user selecting the quality parameters for transcoding the video file by means of selecting a codec and a resolution; storing the quality parameters in a JSDL (Job Submission Description Language) file previously generated by the GRID connector module which is a module communicating the GRID middleware with the multimedia application of the device by means of an application interface; sending a transcoding run request together with the JSDL file to the GRID through the GRID connector module from the user device by means of using Application Programming Interfaces, APIs, included in the GRID middleware; generating a transcoded video file by means of running the transcoding in the GRID with the parameters stored in the JSDL file; storing said video file in a GRID user file system; playing back the video file. As has been mentioned above, said selection in the video file selection phase is carried out in a mode selected from: a direct mode, when the video file is stored in the GRID user file system, selecting the file by means of direct access to said system, an indirect mode, when the video file is stored in the network server, selecting the file by indicating its exact location by means of a URL. In the event that the verification phase obtains as a result that the user is not registered, an additional phase is carried out which comprises the GRID middleware requesting the credentials from the user and performing a process of registering the user in the GRID. When the phase of selecting the quality for transcoding the video file is carried out, a default option optimising the transcoding parameters for playing it back depending on the given device is provided. The phase of generating the transcoded video file comprises performing it in a mode selected from: when the video file is stored in the GRID user file system, the video file resulting from transcoding is stored in the GRID file system, the GRID file system sending an end of process notification to the transcoding/play back application, the file being available from that moment for play back; when the video file is stored in the network server, selecting the file by indicating its exact location by means of a URL, transcoding is performed and at the same time playing back the file is enabled, sending it to the terminal using streaming techniques. Furthermore, during the phase of verifying that the user is registered in the GRID, the accesses to the GRID user file system and the phase of generating the transcoded video file are done by means of using XtreemOS-MD technology implemented in the GRID middleware. The phase of storing the quality information in a JSDL file additionally comprises storing information of the process which must be run in the GRID and of the memory and CPU resources necessary for running the transcoding. On the other hand, the present invention further claims a system comprising the following modules: a GRID connector module implemented in the GRID middleware communicating the GRID middleware with the multimedia application of the device by means of an interface, it manages the access to, sending and running of processes in the GRID, determines when a process ends and handles possible errors and incidents occurring during the transcoding process by means of using APIs provided by the GRID middleware, a GRID file system connector implemented in the GRID connector module comprising means for managing the list of files and directories located in the GRID user file system and means for the user to select the video file to be transcoded. The GRID connector module comprises means which allow the user to pause, resume and/or cancel the audio file transcoding process and further comprises means for generating files in JSDL format where the process which must be run in the GRID and the transcoding parameters previously specified by the user are stored. The main advantages of the present invention with respect to the state of the art are: 1. It allows multimedia terminals with limited computing power to play back any type of video due to the possibility of carrying out a video transcoding process in the GRID. 2. It allows running a transcoding application which is specific to each terminal. The GRID therefore does not need to provide a generic transcoding application, which on the other hand adds certain complexity to the GRID since it must determine the type of terminal and its features in order to perform the optimum coding. Having the specific application of the terminal, running the application in the GRID will be sufficient for obtaining the expected result (result suitable for playback in the terminal). 3. It saves user bandwidth. Given that both the video which is coded and the transcoding task are outside the terminal (i.e., in the GRID), and the user does not need to install any additional application in any other personal device (PC, etc), so there is no need for downloading the original video in the device. The video will be directly coded according to the user needs. Furthermore, in the case of offering a site where the video is stored through a URL, the process of downloading the original video will be carried out by the GRID, not by the user device, saving user bandwidth. 4. It offers the service infrastructure providers the capacity to deploy services in the terminals of the clients. By using this approach, a service provider will not need to develop complex web interfaces or APIs for each type of multimedia application. On the other hand, the terminal application providers will not need to modify their applications for the use of said Web APIs. Instead, by including GRID middleware in the terminal, most of the application will be ready to be run in the GRID. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows the block diagram of the different modules identified in scenarios 1 and 2. FIG. 2 shows the architecture of the transcoding application where the different modules forming it are shown. DESCRIPTION OF PREFERRED EMBODIMENTS An embodiment of the invention is described below in an illustrative and non-limiting manner referring to the numbers used in the drawings. FIG. 1 shows the block diagram of the different modules identified in scenarios 1 and 2, which are the Internet ( 1 ), a multimedia contents provider ( 2 ), the GRID ( 3 ), the GRID part responsible for transcoding video (Scenarios 1 and 2) and video streaming (scenario 2) ( 4 ), a GRID user file system ( 5 ), a user terminal ( 6 ), the client part of the user application for playing back the video (client part of the multimedia transcoder/player) ( 7 ) and the middleware, GRID operating system of the user terminal ( 8 ). The user terminal could be a Nokia® N800, for example, which can be considered today as an equipment having low computing capacity, since it has a memory of 256 MB (any PC has more than 1 GB of RAM) and an OMAP 2420 Texas Instruments® processor with a processing capacity of the order of 500 MIPS (millions of instructions per second). FIG. 2 shows the architecture of the transcoding application, where the different modules and elements forming it are shown, which allows performing video transcoding together with the XtreemOS-MD GRID middleware following the indicated process. The elements shown in the figure are the Internet ( 10 ), a multimedia contents provider ( 11 ), the GRID ( 12 ), the GRID part responsible for transcoding video (Scenarios 1 and 2) and video streaming (scenario 2) ( 13 ), a GRID user file system ( 14 ), the GRID middleware ( 15 ) installed in the user terminal, including the module for GRID authentication ( 20 ), module for performing works in the network ( 21 ) and for managing and setting up the GRID file system ( 22 ), module for the multimedia player application capable of playing back multimedia contents stored in the file system or downloading them by means of streaming ( 16 ), a GRID connector module ( 17 ) which allows the play back application to control and manage the video transcoding tasks through GRID middleware ( 15 ), a GRID system connector module ( 18 ) which allows the play back application to select the file which must be played back from the user file system of the GRID ( 12 ) and a user terminal ( 19 ). Hereinafter the video transcoding/play back application of the device will be called GPlayer for the sake of simplicity. The GPlayer application ( 16 ) provides a user interface which will be run on the user terminal, which will be used by the user to select the video to be transcoded and played back. To start the application, the GRID middleware ( 15 ) is run in order to verify that the user has been previously authenticated in the GRID ( 12 ). If not, the user credentials will be requested by the middleware, carrying out the registration process in the GRID. The application ( 16 ) uses a GRID connector module ( 17 ) for use in the GRID ( 12 ) which in turn contains a GRID file system connector ( 18 ) accessing the GRID user file system ( 14 ) through the GRID middleware ( 15 ). The GRID connector module ( 17 ) manages the access and sending of processes to the GRID ( 12 ) and controls the run of the transcoding processes, determining when a process has ended and handling the possible errors or incidents which can arise during the transcoding process. The GRID connector module uses the APIs of the GRID middleware. The application offers the possibility of transcoding and playing back both video files stored in the GRID user file system (Scenario 1), and files which the user does not have direct access to and the location of which is indicated by means of a URL (Scenario 2). A connector is necessary for scenario 1. This connector is the GRID file system connector ( 18 ), a module which is used by the GPlayer application ( 16 ) for providing the list with all the files and directories located in the user file system of the GRID ( 12 ). This connector allows the user to choose which file from those available in the GRID user file system will be transcoded/played back. The application will also offer the user the possibility of selecting the desired quality for transcoding video which will be played back from the possible codec and resolution options supplied by the terminal. There will be a default option and, it will generally be the optimum option in terms of playback quality with the given terminal. The client part of the application ( 16 ) will launch a transcoding process run request to the GRID by means of using the APIs offered by GRID middleware ( 15 ) once the video file which must be played back and the desired quality are selected. To that end, the work to be performed in the GRID is specified through a file in JSDL (Job Submission Description Language) format which will be generated by the GRID connector module ( 17 ), adding the suitable transcoding parameters according to the options selected by the user. The JSDL file will indicate that the work to be performed in the GRID ( 12 ) is the GRID part of the GPlayer application ( 16 ) which could be located in the GRID user file system ( 14 ), or if not, they will be copied in said file system before starting its run in the GRID. Then, the GRID will perform the transcoding task. In scenario 1, the transcoder will have the original video file as input, generating a transcoded video depending on the input parameters indicated in the JSDL file. The GRID connector module ( 17 ) controls that the process is suitably run in the GRID during the transcoding process: if an error were to occur in the process, the GRID connector module ( 17 ) will send an error notification to the GPlayer application ( 16 ). The GRID connector module ( 17 ) also allows the user to pause, resume and/or cancel the transcoding process. The resulting video is stored in the user distributed file system ( 14 ). The client part of the GPlayer application ( 16 ) will receive a notification once the transcoding process ended, the playing back of the transcoded video being started. In scenario 2, the application of transcoder downloads the original file from the indicated URL ( 11 ), starting the transcoding process and providing the transcoded file which has been generated at the same time using streaming techniques (GPlayer usually only implements scenario 1). The GPlayer ( 16 ) will use the capacities offered by XtreemOS-MD (XtreemOS for mobile devices) implementing the GRID middleware ( 15 ) in all cases for carrying out the operations of authenticating the GRID ( 12 ), performing work in the GRID ( 12 ) and the access to the user file system.
The present disclosure relates to the production of an application for transcoding video files for devices having limited computing power by means of using a grid computing platform. The platform offers storage space for the user (making use of the distributed storage capacity of the GRID platform and its own security mechanisms) where both the original video and the transcoded video will be stored. The solution also provides the device with middleware with GRID capacities in order to achieve complete GRID integration. That means that the transcoding application could either be run directly in the terminal or in the GRID.
7
This invention relates to attachment nuts in general, and specifically to a means for preventing a conventionally threaded nut from loosening. BACKGROUND OF THE INVENTION Attachment nuts that incorporate an anti-loosening feature or anti-back up feature, generally referred to as lock nuts or torque nuts, are well known in the art. These attachment nuts often have threads designed to deform as the nut is tightened down with a predetermined amount of torque, preventing it from loosening thereafter. A typical application for such fasteners in the automotive industry is to fix a wheel bearing assembly to the end of a shaft. While they work well mechanically, the common drawback to such fasteners is cost. Besides being much more expensive initially than a conventionally threaded nut, they are, by definition, not reusable, since they deform at final tightening. It would be desirable, if possible, to provide a workable, economical anti-loosening capability for a conventionally threaded, reusable nut. SUMMARY OF THE INVENTION The invention provides such an economical alternative. A retainer cooperates with a specially configured portion of the shaft to prevent a conventionally threaded, hex sided attachment nut from loosening. The preferred embodiment is disclosed in an automotive application, specifically for attaching a driven front wheel bearing assembly to an axle shaft. The shaft has a threaded portion near, but not directly at, the end thereof. On that part of the shaft adjacent the threaded portion is formed a series of axially extending, circumferentially spaced splines. In addition, in the embodiment disclosed, there is a circumferential groove formed in said shaft between the splines and the end of the shaft. The nut slides over the end of the shaft without engaging the splined portion of the shaft, where it then engages the shaft threaded portion and may be turned down to its tightened position, against a shoulder of the bearing assembly that it attaches. The invention also includes a slip on retainer having a skirt sized so as to fit non-turnably over the outside of the hex nut and a generally cylindrical sleeve adjacent the skirt and and sized so as to fit over the splined portion of the shaft. In the embodiment disclosed, the sleeve also includes a tab that fits into the shaft groove. A series of circumferentially spaced fingers is lanced into the retainer sleeve, which extend radially inwardly far enough to be able to fit between the splines. Furthermore, the splines are oriented so as to flex freely over the splines if the retainer is turned in the tightening direction of the nut, but to be blocked between the splines if it is attempted to turn the retainer in the other direction. Significantly, the fingers mismatch the splines in number, being one less. After the nut has been threaded to its tightened position, or close to it, the retainer skirt may be pushed over the outside of the nut as the sleeve fits over the shaft splines and the fingers slide axially along the splines. When the retainer is fully seated, the tab fits into the shaft groove. The mismatch between the number of fingers and splines assures that one finger will be located directly between an adjacent pair of splines, whatever the rotational position of the nut, as opposed to all fingers resting on top of a spline, as could occur with a matched number. Therefore, the retainer, and the nut to which it is non turnably attached, will not be able to turn significantly in the loosening direction before the one finger is blocked, thereby preventing further turning. The tab and groove, meanwhile, serve to assure that the retainer skirt does not slide off of the outside of the nut. It is, therefore, an object of the invention to economically provide an anti-loosening capability to a conventional attachment nut. It is another object of the invention to provide such a capability with a retainer and a specially configured portion of the shaft adjacent to the threaded portion of the shaft which cooperate to assure that the nut cannot be turned significantly back from its tightened position. It is another object of the invention to provide such a cooperating retainer and shaft portion in which a series of fingers on the retainer is mismatched in number relative to a series of splines on the shaft, so that, whatever the position of the nut relative to the splines when it is tightened, one finger will be blocked by a spline to prevent the nut from turning back significantly. DESCRIPTION OF THE PREFERRED EMBODIMENT These and other objects and features of the invention will appear from the following written description, and from the drawings, in which: FIG. 1 is a view showing the end of the shaft in elevation and a front wheel bearing to be attached thereto in cross section; FIG. 2 is a sectional view taken along the line 2--2 of FIG. 1; FIG. 3 is a view of just the end of the shaft as in FIG. 1, but with the nut in tightened position; FIG. 4 is a side view of the retainer before it is installed; FIG. 5 is a sectional view taken along the line 5--5 of FIG. 6; FIG. 6 is a view like FIG. 3, but after the retainer has been installed. Referring first to FIGS. 1, 2 and 3, the invention is used to attach a driven front wheel bearing 10 to the axle shaft, designated generally at 12. Shaft 12 has a threaded portion 14 near, but not directly at, the end thereof. A series of ten axially extending, evenly circumferentially spaced splines, each designated generally at 16, is formed on shaft 12. Splines 16 are adjacent to threaded portion 14, but do not extend all the way out to the end of shaft 12. As best seen in FIG. 2, splines 16 have an outermost diameter that is less than the outermost diameter of the threaded portion 14, and each has a flat face 18 on the right side and a sloped face 20 on the left side, for a reason described below. While a conventional shaft 12 will have the threaded portion 14, it will not have the splines 16. However, splines 16 may be very economically roll formed to shaft 12 when shaft 12 is initially manufactured, without changing its basic size or configuration. In addition, there is a circumferential groove 22 cut into shaft 12, between the end thereof and the splines 16. A conventionally threaded hex sided nut 24 slides over the end of the shaft 12 without engaging the splines 16, because of the relative diameters noted above, and threads onto threaded portion 14 as far as a tightened position shown in FIG. 3, where it bears on a washer 26. Washer 26, in turn, bears on a shoulder of bearing 10, thereby fixing bearing 10 to shaft 12. Splines 16 and groove 22 cooperate with other structure of the invention, described next, to keep nut 24 from backing off from the tightened position. Referring next to FIGS. 4 and 5, the invention also includes a slip on retainer, designated generally 28, which is formed conveniently as a one piece metal stamping. Retainer 28 has a hex shaped skirt 30 that is sized to slip fit closely and non-turnably over the outside of hex nut 24, but not so tightly as to be difficult to apply. A cylindrical sleeve 32 adjacent skirt 30 is sized so as to fit over splines 16 as skirt 30 is pushed onto nut 24. Lanced into sleeve 32 is a series of nine evenly circumferentially spaced fingers 34. The material of retainer 28 has enough resilience that the fingers 34 are resilient and flexible. As best seen in FIG. 5, fingers 34 extend radially inwardly far enough to be able to fit between the splines, 16, and are sloped in the same direction as the spline faces 20, for a purpose described below. Finally, in the embodiment disclosed, sleeve 32 also includes a tab 36 sized so as to fit into shaft groove 22, which may be resilient with a permanent downward bend, or deformable, and initially straight. The operation of the invention may be understood by referring to FIGS. 5 and 6. After the 24 nut has been threaded to its tightened position, or close to it, the retainer skirt 30 may be pushed over the outside of the nut 24. Concurrently, sleeve 32 slides over splines 16 and the fingers 34 slide axially along the splines 16. Once skirt 20 is fully seated, tab 36 fits into groove 22, either by snapping in automatically, or by being later bent down. This assures that retainer 28 can not slide axially back off. The mismatch between the number of fingers 34 and splines 16, the fingers 34 being one fewer, assures that not all fingers 34 can rest on top of a spline 16, that is, at the juncture of the spline faces 18 and 20, whatever the rotational position of nut 24 relative to the splines 16. Therefore, one finger, in this case designated 34' will be located directly between an adjacent pair of splines 16, that is, with the end of finger 34' against or very close to, a spline flat face 18'. If nut 24 is not fully tightened when retainer 28 is seated, it may be turned further, in the clockwise direction of FIG. 5. Again, because of the mismatch of splines 16 and fingers 34, even with further turning of nut 24, the end of some finger 34 will rest against or close to a spline back face 18. Therefore, if it were attempted to turn the nut 24 and retainer 28 in the opposite direction, counterclockwise as seen in FIG. 5, the one finger 34' would be blocked by the spline face 18' before the nut 24 and retainer 28 could turn significantly. The greater the number of splines 16 and fingers 34, so long as they are mismatched by one, the closer a finger 34 is likely to rest to a spline flat face 18, and the more immediate will be the blocking action in the event of an attempt to loosen nut 24. Bending tab 36 back up and pulling retainer 28 would allow nut 24 to be threaded off, and both nut 24 and retainer 28 would be reusable. Thus, a low cost alternative to the expensive lock nut described above is provided. Variations of the preferred embodiment described above may be made within the spirit of the invention. If it were not necessary to turn nut 24 any more after retainer 28 was installed, then it would not be necessary for fingers 34 to be freely flexible in the tightening direction, so long as they were inflexible in the loosening direction. Then, the spline sloped faces 20 would not be necessary, and a greater number of splines 16 could be formed in the space available, which as noted above, could be an advantage. However, it is still an advantage to be able to turn nut 24 after retainer 28 has been installed, which also allows retainer 28 to be attached to nut 24 before it is threaded on, if desired, since turning in the tightening direction would not be impeded. Attaching retainer 28 permanently, or through a tight press fit, would allow tab 36 and groove 22 to be dispensed with, since the retainer 28 would not be subject to slipping off. However, all the features of the embodiment disclosed, including the orientations of the spline faces 20 and fingers 34, the easy slip fit of skirt 30 to nut 24, and the tab 36 and groove 22, cooperate to allow retainer 28 to be easily applied after nut 24 is already threaded on, and to allow nut 24 to be further turned, if necessary, after retainer 28 is applied.
An economical alternative to throw away lock nuts is provided by a retainer that fits to or over a conventionally threaded nut. Splines on the shaft, and resilient fingers on the retainer, are mismatched in number by one, assuring that they interfit with at least one finger blocked by a spline, or closed to it, so that the nut cannot be turned significantly back. The retainer can be easily removed, so that both it and the nut may be reused.
8
STATEMENT OF GOVERNMENT INTEREST The invention described herein may be manufactured and used by or for the Government for governmental purposes without the payment of any royalty thereon. BACKGROUND OF THE INVENTION At radio frequencies, superheterodyne receivers typically have sensitivities that are orders of magnitude higher than those of direct detection receivers. Such superheterodyne receivers, in addition to a signal source, usually require a separate local oscillator or pump source. With certain constraints, superheterodyne receivers can be realized with just one source. The output from this source is divided and one of the component signals is Doppler shifted. The Doppler shifted component serves as the local oscillator source and the unshifted component serves as the signal source or vice versa. At submillimeter wavelengths, however, presently known electronic means of frequency shifting are very inefficient and produce very small output power levels. Reflection of a signal from a metallic surface which is in linear motion will produce a constant Doppler shift of the reflected signal. As a practical matter, however, linear motion can only be sustained for limited periods of time. For a continuously Doppler shifted signal, some kind of repetitive process of linear motion must be employed. Imperfections in presently known mechanical means for frequency shifting make it impossible to generate a single Doppler shifted frequency. Instead, a spectrum of frequencies is generated which has a frequency spacing which is the reciprocal of the period of the time repetitive process. This spectrum has a maximum amplitude at or near the frequency determined by the ratio of the velocity component of the reflector (or reflectors) in the direction of wave propagation and the wavelength. The spectral line of maximum amplitude is surrounded by other spectral lines whose amplitudes depend on the "smoothness" of the repetitive process. A spectrum of frequencies, rather than a single frequency, is undesirable in certain applications, such as in radar applications, where they may lead to ambiguities. One way to eliminate this problem is to space the non-desirable lines far apart from the desired one. This requires a mechanical process of the highest possible repetition rate. In an article entitled "High Sensitivity HCN Laser Interferometer For Plasma Electron Density Measurements" by D. Veron, which article appears in Volume 10, Number 1 of Optics Communications, dated January 1974, there is described a rotating mechanical frequency shifter which is, in effect, a large rotating paddle wheel. Each paddle reflects the signal over a small angle of rotation, where its motion can be considered as being linear. Then it is replaced by the next paddle. Although high Doppler offsets may be achieved with high tangential speed of the paddle, many paddles are required to satisfy the linear motion approximation. Consequently, the wheel will have a large diameter and a slow rate of rotation thus producing a close frequency spacing in the resulting spectrum. In an article entitled "CW IR Laser Induced Chemistry, Isotope Separation and Related Laser Technology at NRL" by T. J. Mannucia, which article appears in Laser in Chemistry, pages 210-215, Elsevier Scientific Publication Company, dated 1977, there is described another mechanical Doppler frequency shifting scheme based upon multiple reflections between a stationary involute spiral cylinder and a multiplicity of mirrors attached to a concentrically rotating cylinder. The transmissive scheme as described by Mannucia, where radiation enters in an axial direction at one end of the cylinder and leaves at the other end of the cylinder, neglects the axial spreading between reflection points as reflections occur at increasing radial distances on the involute cylinder. In addition, it does not provide means to make the Doppler shifted signal phase coherent between cylinder revolutions and hence an undesirable spectral spreading will occur. In U.S. Pat. No. 4,264,141 issued to Karl Guers et al on Apr. 28. 1981, there is disclosed an arrangement of apparatus for frequency shifting a monochromatic narrow bandwidth light beam. Unlike the Mannucia device and the present invention, the Doppler shifting curved surfaces are not involutes of circles. Like the Mannucia device, however, it is a transmissive type device, and not a device in which an input signal is reflected back upon itself, as is the case in the present invention. The Guers et al patent requires pairs of stationary and pairs of rotating reflectors in order to function. A continuous wave device employing several pairs of Doppler shifting mirrors would therefore be physically large in comparison to the present invention. Furthermore, no provisions have apparently been made for a phase-continuous transition from one frequency shifting contour to the next, which is essential in narrowing the output spectrum. OBJECTS AND SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a rotating Doppler frequency shifter device of improved construction and performance. It is another object of the present invention to provide a rotating Doppler frequency shifter device especially adapted for use in the submillimeter wavelength range. It is a further object of the present invention to provide a rotating Doppler frequency shifter device which is efficient in providing high output power levels in its frequency range of operation. It is a further object of the present invention to provide a rotating Doppler frequency shifter device which is mechanically tunable to achieve an output signal of the narrowest spectral width for a given input frequency. In accordance with the present invention, a rotating Doppler frequency shifter device comprises several identically shaped spiral members which surround a first mirror affixed to a rotating shaft and a second mirror affixed to an arm which extends radially from the shaft and rotates therewith. Each spiral member, which may be mechanically tuned, has a reflective inner surface which varies in distance from the mirrors and is shaped such as to reflect a signal impinging thereon back upon itself. This arrangement provides for continuous Doppler frequency shifting of the input signal and an output signal of the narrowest spectral width for a given input frequency. BRIEF DESCRIPTION OF THE DRAWINGS The foregoing and other objects, features and advantages of the present invention will become more apparent upon reading the following detailed description thereof in conjunction with the drawings. FIG. 1 is a geometric representation of a ray being directed by a rotating mirror onto the reflective interior wall of a cylinder. FIG. 2 is a geometric representation of a rotating Doppler frequency shifter utilizing a single involute spiral reflective surface. FIG. 3 is a pictorial representation of a preferred embodiment of the rotating Doppler frequency shifter of the present invention. FIG. 4 is a pictorial representation of an alternate embodiment of a spiral member of the present invention. FIGS. 5-8 are end views and sectional views taken through the spiral member depicted in FIG. 4. FIG. 9 is a pictorial representation of a further embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION Referring now to FIG. 1 of the drawings, there is depicted a ray 12 entering the paper plane perpendicularly along an axis Z orthogonal to axes X and Y. Ray 12 is deflected into the paper plane by a mirror 16 which is located at the origin and is oriented upwardly at a forty five degree angle from the paper plane. Mirror 16 rotates with an angular velocity Ω around axis Z which is in line with the arriving ray 12. At the point P, ray 12 is retroreflected back on itself by the wall of a circular cylinder 18 of radius r and concentric with the axis Z. After that, ray 12 is retroreflected by mirror 16 along the path of its arrival. This assumes that mirror 16 has turned insignificantly, while the ray 12 traverses the distance 2r. Although ray reversal has been achieved, no Doppler shift is realized because of the constant path length along the radius r. In FIG. 2, however a reflecting surface is formed on the inner wall of a spiral member 20 whose spiral shape is the involute of a circle. Such a spiral may be formed, for example, by tracing the end of a taut string which is unwound from the circumference of a circle of radius a. Spiral member 20 has the polar equation θ=→(r/a).sup.2 -1 -tan.sup.-1 →(r/a).sup.2 -1 (Eq 1) and has two important characteristics. Length s, which is the tangent to the circle 22 at point P1 and extends to point P2, is proportional to the rotational angle Ωt. It is also orthogonal to the spiral member 20 at point P2, independent of its angle Ωt. A ray striking the center of mirror 26 which, like mirror 16 of FIG. 1 is positioned at the central axis Z and at a forty five degree angle from the paper plane, is reflected to point P1 on mirror 28 and thence to point P2 on spiral member 20. Mirror 28 is perpendicular to the paper plane and made to rotate together with mirror 26 at a distance "a" from the central axis Z. A ray striking the spiral member 20 is reflected on itself and leaves on the same path as it had entered. If a spiral member covering 360 degrees of revolution is provided, as shown in FIG. 2, and if the change of length s per complete revolution is an integer multiple of half the wavelength λ/2, assuming this is a reflective device, then the Doppler shift experienced by the signal is: Δf=d/dt (2s/λ)=2Ωa/λ (Eq. 2) If the change of length s is not an integer multiple of half of a wavelength, the Doppler shifted signal will be phase modulated and spectrally broadened. It will be noted that r does not change linearly with Ωt, but s does. Also that s is the instantaneous radius of curvature of spiral 20. FIG. 3 is a perspective view of a preferred embodiment of the present invention. Instead of using one spiral member with one step of Δs, per 360 degree rotation, a preferred embodiment of the present invention uses four spiral members 50 mounted on a plate 52 with steps of Δs/4 per 90 degrees of rotation. It is possible to use four members with steps of Δs/4 per 90 degrees of rotation or any odd or even number of members, as long as each step is an integer multiple of λ/2. Each member has exactly the same spiral shape, and is not merely the succeeding portion of the same involute. Such arrangements are much easier to manufacture than the piror art devices and provide smaller radial pathlength changes for the signal, which is important because of the rapid defocusing of submillimeter waves. As seen in FIG. 3, a first mirror 54 is attached to the shaft 56 of a motor 58 mounted below plate 52. Motor 58 spins mirror 54 at an angular speed Ω about the central axis of the spiral members 50. A second mirror 60 is attached to the shaft 56 by a side arm 62 which extends radially therefrom. Mirrors 54 and 60 are oriented in the same manner as the mirrors 26 and 28 of FIG. 2. The reflective surfaces of spiral members 50 have a radial separation of nλ/2 at their ends. In operation, an input signal ray 66 impinges on mirror 54 which together with mirror 60 is rotating at a speed Ω. Ray 66 is reflected by mirror 54 to mirror 60 and thence to the reflective surface of a spiral member 50. Because of the particular curvature of the reflective surface of member 50, ray 66 is reflected back upon itself to retrace its path back to its source. As mirrors 54 and 56 rotate, the distance the ray 66 must travel increases linearly until it reaches the end of a member 50, where it abruptly decreases. This action is repeated as ray 66 traverses the next spiral member 50. This repetitive action produces the desired linear sweep and the resultant constant Doppler shift of the input ray 66. The requirement for the radial transitions between segments 50 to be integer multiples of λ/2 necessitates narrow mounting tolerances for the members at submillimeter wavelengths. Also, a device with rigidly mounted members 50 will only work optimally at a single input frequency. In order to alleviate construction tolerances and to make the frequency shifter useful over a range of input frequencies, members 50 are each mounted in such a way on plate 52 that they can be rotated around an axis 68 at one end thereof and perpendicular to plate 52. At the other end of each member 50, a radial adjustment as shown by arrows 70 is achieved with a mechanical screw-type adjuster 72. For clarity of the drawing, only one of the spiral members 50 is shown having such a mechanical screw-type adjuster 22. If nλ/2 is much larger than λ/4, the maximum required adjustment range, then adjustments will not upset the reflection geometries noticeably. It will be appreciated that the reflecting inner surface of each spiral member 50, being linear rather than curved in the vertical plane, may disturb the symmetry of an input beam of finite diameter. In most applications, this may be acceptable, especially since this effect is minimized at larger radii of curvature and with smaller beam diameters. A further improvement in beam symmetry can be achieved however, by making the vertical surface conform instead to the radius of curvature in the horizontal plane at each angular location. As seen in FIGS. 4-8 of the drawings, a spiral member 78 may be curved along its height as well as along its length. The radius of curvature in the height dimension varies as the radius of curvature along its length. As seen in the end and sectional views of FIGS. 5-8, at each angular position θ the curvature is circular with a radius of curvature s. The radius of curvature s, however, will be seen to increase as θ increases. The result of this dual curvature of a spiral member 78 is that the distortion of a beam of finite diameter is minimized. Higher Doppler frequencies can be achieved by adding one or more additional mirrors on the arm 62 of shaft 56. As shown in FIG. 9 of the drawings, an additional mirror 80 has been affixed to arm 62 and mirror 60 has been tilted slightly to direct the ray 82 downwardly to spiral member 50, where it is now directed towards mirror 80. The ray impinges on mirror 80 perpendicularly and is reflected back on itself. It will be appreciated that the vertical height or wall of spiral member 50 may have to be increased to account for the fact that the ray travels down the spiral member as the motor shaft turns. Also, the vertical extent of the additional mirror 80 must be sufficient to intercept the ray as it travels down the surface thereof. Also, should this embodiment of the invention be implemented with spiral members that are curved in their height as well as their length dimension, then the curvature in the height dimension will differ from the curvature used in spiral members 78 in order to account for the traveling of the beam down the reflective wall of the spiral member. The rotating Doppler frequency shifter described herein is of particular usefulness at submillimeter wavelengths. It should be noted however, that there are no conceptual restraints in applying the same techniques from millimeter to infrared or even to visible wavelengths. Although the invention has been described with reference to particular embodiments thereof, it will be understood to those skilled in the art that the invention is capable of a variety of alternative embodiments that come within the spirit and scope of the appended claims.
A rotating Doppler Frequency shifter comprises spiral members which surround a first mirror affixed to a rotating shaft, and a second mirror affixed to an arm which extends from the shaft and rotates therewith. Each spiral member has a reflective inner surface which is shaped such as to reflect a signal impinging thereon back along its entry path. This arrangement provides for a continuous Doppler frequency shifting of the input signal.
6
FIELD This invention relates to a device for filtering contaminants, such as particulates and vapor phase contaminants, from a confined environment such as electronic or optical devices susceptible to contamination (e.g. computer disk drives). Specifically, the filter assembly filters contaminates from the inlet air as well as contaminates that are generated from within the device. BACKGROUND Many enclosures that contain sensitive equipment must maintain very clean environments in order for the equipment to operate properly. Examples include enclosures for the following: optical surfaces or electronic connections that are sensitive to particulates and gaseous contaminants which can interfere with mechanical, optical, or electrical operation; data recording devices, such as computer hard disk drives that are sensitive to particles, organic vapors, and corrosive vapors; processing and storage of thin films and semiconductor wafers; and electronic controls such as those used in automobiles and industrial applications that can be sensitive to particles, moisture buildup and corrosion as well as contamination from fluids and vapors. Contamination in such enclosures originates from both inside and outside the enclosures. For example, in computer hard drives, damage may result from external contaminates as well as from particles and vapors generated from internal sources. The terms “hard drives” or “hard disk drives” or “disk drives” or “drives” will be used herein for convenience and are understood to include any enclosure for equipment or material that is sensitive to contamination. Disk drives must be protected against a large number of contaminants that are found in the surrounding environment and can penetrate the drive. This is particularly true for drives that are removable and portable to any environment such as disk drives that are used in laptop computers or in Personal Computer Memory Card International Association (PCMCIA) slots, or other drives which may not be used in the typical data processing environment. Drives used in applications such as gaming systems, personal video recorders, automotive mapping systems and others must survive in environments that are more severe than that of standard desk top computer applications. Contamination may occur in various forms. For example, disk drives are susceptible to corrosive ions, such as chlorine and sulfur dioxides, and may also be sensitive to variations in humidity. Accordingly, an array of failure mechanisms exist. One serious contamination-related failure mechanism in computer disk drives is static friction or “stiction.” Stiction results from the increased adhesion of a drive head to a disk while the disk is stationary plus increased viscous drag parallel to the head-disk interface. Newer high-density disks are more sensitive to contamination-caused stiction because they are smoother and include relatively thin layers of lubricants. Contaminants on the disk change the surface energy and increase the adhesive forces between the head and disk, causing stiction. Also, stiction may be caused by vapors condensing in the gap between the head and disk. The low energy low torque motors that are being used in smaller disk drives for portable computers and the low noise drives used in other applications, such as personal video recorders, are increasingly sensitive to stiction related failures. Another serious contamination-related failure mechanism is a head crash. Head crashes can occur when particles get into the head disk interface. The spacing or flying heights between the head and disk during operation of modern high density drives is 30 nanometers or less. As rotational speed affects the maximum data transfer rate a drive can have, rotational speed of modern disk drives is increasing. Some current drives operate at 15,000 revolutions per minute and future drives will likely use even higher speeds. With such high speeds and low flying heights, even submicron-sized particles can be a problem, causing the head to crash into the particle or the disk after flying over a particle, bringing the drive to an abrupt failure mode. Particles can also adversely affect data integrity and mechanical reliability of a drive, sometimes referred to as thermal asperity. Disk Drives are also susceptible to variances in humidity. Low humidity is problematic either because it may increase static electricity or decrease lube thickness or functionality. However, in high humidity, corrosion is promoted and lubricants may swell. It takes significantly more adsorbent to protect a drive from humidity than it does from organic or acid gas contamination. Thus drives that need buffering from humidity fluctuations require significant amounts of adsorbent. To prevent contamination-related failure, a variety of filtration devices have been used. For example, filtration devices to keep particles from entering disk drives are well known. Some consist of a filtration media held in place by a housing of polycarbonate, acrylonitrile butadiene styrene (ABS), or some other material. Others consist of a filtration media in the form of a self-adhesive disk utilizing a layer or layers of pressure sensitive adhesive. Such filters are mounted and sealed over a vent hole in the enclosure to filter particulates from the air entering the drive. Filtration performance depends not only on the filter media having a high filtration efficiency but also on having it have a low resistance to airflow. If the pressure drop is too high, unfiltered air will leak into the enclosure through a gasket, screw hole, or other seam instead of entering through the filter. Such filters may work well for particulates of external origin, but do not address the problems from vapor phase contaminants. Internal particulate filters, or recirculation filters, are also well known. These filters are typically pieces of filter media, such as expanded PTFE membrane laminated to a polyester nonwoven backing material. Other recirculation filters are “pillow-shaped” filters containing electret (i.e., electrostatic) filter media. These filters may be pressure fit into slots or “C” channels and are placed in an active air stream such as near the rotating disks in a computer hard disk drive or in front of a fan in electronic control cabinets, etc. Alternatively, the recirculation filter media can be held in a plastic frame. Still alternatively they can be applied to the sides of components or the housing to allow for particle collection. Recirculation filters work well for particulate removal of internally generated particles but do not address the problem of vapor phase contaminants, nor do they provide protection from external particles entering the drive. Internal adsorbent filters are also well known. One example is described in U.S. Pat. No. 4,830,643 issued to Sassa et al. This patent teaches a sorbent filter where a powdered, granular or beaded sorbent or sorbent mixture is encapsulated in an outer expanded PTFE tube. This filter is manufactured by W. L. Gore & Associates, Inc., Elkton, Md., and is commercially available under the trademark GORE-SORBER® module. A second well known internal adsorbent assembly is described in U.S. Pat. No. 5,593,482 issued to Dauber et al. A third internal adsorbent assembly incorporates a layer of adsorbent such as activated carbon/PTFE composite between two layers of filter media or is alternately wrapped in a layer of filter media and can be installed between slots or “C” channels much the way a recirculation filter is installed but without significant airflow through the filter. Such a filter is described in U.S. Pat. No. 5,500,038 issued to Dauber et al. Known internal adsorbent filters work well at adsorbing vapor phase contaminants, but they do not filter particulates very well. They may collect particles by some impaction of particles onto the filter (i.e., by having the larger particles impacting or colliding with the adsorbent filter as particle-laden air speeds around the filters) or by diffusion of particles onto the filter. However, these filters do not perform nearly as well as the standard recirculation filters, which work by a combination of sieving (mechanically capturing particles too large to pass through the pore structure of the filter), impaction (capturing particles too large to follow the bending air streams around filters or the fibers of the filter), interception (capturing particles that tend to follow the air streams, but are large enough to still intercept a filter fiber or in other words those particles with a diameter equal to or less than the distance between the fiber and the air stream line), and diffusion (capturing smaller particles buffeted about by air molecules in a random pattern and coming into contact with a filter fiber to become collected). Because there is a need to remove vapor phase contaminates as well as particles from both internal and external sources, combination sorbent breather filters were developed. These can be made by filling a cartridge of polycarbonate, ABS, or similar material with sorbent and securing filter media on one or both ends of the cartridge and placing the cartridge over a hole in the container wall. These filters effectively cleanse incoming air of particles and vaporous contaminates, and internal air of internally generated vaporous contaminates. Because the filters are inside, the vaporous drive contaminate will diffuse into the adsorbent sections of the filters. Examples of such filters are described in U.S. Pat. No. 4,863,499 issued to Osendorf (an anti-diffusion chemical breather assembly for disk drives with filter media having a layer impregnated with activated charcoal granules); U.S. Pat. No. 5,030,260 issued to Beck et al. (a disk drive breather filter including an assembly with an extended diffusion path; U.S. Pat. No. 5,124,856 issued to Brown et al. (a unitary filter medium with impregnated activated carbon filters to protect against organic and corrosive pollutants); and U.S. Pat. No. 5,447,695 issued to Brown et al. (Chemical Breather Filter Assembly). Unfortunately, many of these designs are too large and take up too much space in today's miniaturized drives. To adsorb corrosive compounds such as chlorine and sulfur dioxide, an adsorbent is typically treated with a salt to chemisorb the contaminants. However, when many known filters are washed in deionized water, large amounts of these salts may be released, which makes them unacceptable in sensitive disk drive environments. A washable adsorbent recirculation filter is described in U.S. Pat. No. 5,538,545 issued to Dauber et al., wherein expanded PTFE membranes or other hydrophobic materials are used to encapsulate the adsorbent. However, these filters do not filter air as it comes into the drive before it has had a chance to deposit particles and do damage to the drive. A second combination adsorbent breather filter is also well known that encapsulates the adsorbent material such as an impregnated activated carbon polytetrafluoroethylene (PTFE) composite layer between two layers of filter media and is applied over a hole in the enclosure with a layer of pressure sensitive adhesive. These filters work well to an extent and are of a size that can be used in today's small drives and are typically designed to filter air coming into the drive. Thus, the adsorbent is typically primarily designed to adsorb both organic and corrosive vapors from the outside environment and will filter particulates only from air coming into or leaving the drive. Internally generated vapors and moisture can be adsorbed by these filters, but often times they have been used in conjunction with another larger internal adsorbent filter so the adsorbent breather filter can be smaller in size. Therefore, such filters may not contain enough adsorbent to adequately adsorb all the internally generated contaminants and typically will not contain enough adsorbent to control humidity well within the drive as previously mentioned. Again, particles are also generated inside the drive and are not typically captured by these filters. Combinations of several filters having different functions in a single drive have been taught. For example, U.S. Pat. No. 5,406,431, to Beecroft, describes a filter system for a disk drive that includes an adsorbent breather and recirculation filter in specifically identified locations within the drive. Also, U.S. Pat. No. 4,633,349, by Beck et al., teaches a disk drive filter assembly comprising a dual media drum type filter element in a recirculating filter assembly that surrounds a breather filter. Further, U.S. Pat. No. 4,857,087, to Bolton et al., teaches incorporating a breather filter in a recirculation filter housing, but has significantly more parts and incorporates a third filter element complete with housings, apertures, and gaskets to accomplish this inclusion. The combinations described in these patents either locate the filter components in separate regions of the disk drive or incorporate space-consuming fixtures to orient the component parts within the drives. Space saving combinations having further multifunctionality have also been taught. These include U.S. Pat. No. 6,266,208 to Voights integrating a recirculation filter, breather filter, and adsorbent filter into a single unitary filter; U.S. Pat. No. 6,238,467 to Azarian et al., incorporating a breather filter, adsorbent filter, and recirculation filter into a rigid assembly filter; U.S. Pat. No. 6,296,691 to Gidumal incorporating a breather filter adsorbent filter and recirculation filter into a molded filter; and U.S. Pat. No. 6,395,073 to Dauber incorporating the recirculation filter and breather filter with optional adsorbent filter into a low profile adhesive construction. All but the last filter design by Dauber are filters of considerable size and are not appropriate for smaller drives like the 2.5″ laptop drives and smaller 1.8″ drives, 1.0″ drives and 0.85″ drives that are currently in the market and/or in design. As disk drives have become smaller and less expensive, there is a need for simplification and the reduction in the number of parts in a drive to reduce cost and improve performance. However, as the drives increase in recording data density and capacity, they become more sensitive to particulate and vaporous contamination including increased sensitivity to moisture. Existing filtration means often do not meet these demanding filtration requirements. The low profile adsorbent breather filters and low profile multifunction filters best suited in size to fit these smaller drives have had to compromise in adsorbent content because they needed airflow through the filter. The compromise has been to either use very dense adsorbent media and have limited airflow, or use less dense adsorbent media to maintain airflow but then have limited adsorbent capacity. Two recent inventions have tried to overcome this deficiency. U.S. Pat. No. 6,683,746 to Kuroki et. al. allows for air by-pass of the adsorbent media to increase airflow, but can have performance reductions in adsorption if too much air by-passes the adsorbent media. U.S. Pat. No. 6,712,887 to Ueki et. al. uses grooves in the adsorbent media to increase airflow, but this has limited functionality as there are further limitations to airflow through the filtration layer unaddressed by this invention. SUMMARY In one aspect, the invention is an adsorbent breather assembly for removing contaminants within an enclosure having a fluid inlet/outlet port comprising: an adhesive layer; an adsorbent media adjacent to the adhesive layer, in which the adsorbent media has at least a bottom surface and a top surface, and the adsorbent media is in fluid communication with the fluid inlet/outlet port; a flow layer is adjacent to at least one surface of the adsorbent media and a filter media attached to the adhesive layer such that the adsorbent media and the flow layers are encapsulated between the adhesive layers and the filter media. In still another aspect, the invention provides an adsorbent having a bottom surface adjacent to a layer of adhesive. In still another aspect, the invention provides an adsorbent layer having a bottom surface adjacent to the flow layer which is in turn adjacent to the adhesive. In yet another aspect, the invention provides a filter media comprising a porous polymeric membrane. In this aspect, the porous polymeric membrane is preferably hydrophobic. More preferably, the porous polymeric membrane comprises PTFE. In another aspect, the invention provides a filter that includes an electret particle filtering layer disposed on a porous polymeric membrane. An another aspect the invention provides a filter media comprising an electret layer. In still another aspect, the invention provides an adsorbent media comprising PTFE and an adsorbent material. In this aspect, the adsorbent media preferably comprises a PTFE membrane filled with an adsorbent material. In yet another aspect, the invention provides a molded adsorbent media. In a further aspect, the invention provides an adsorbent media including a non-woven fabric impregnated with an adsorbent. In another aspect, the invention provides an adsorbent media including a granular material disposed on at least one side of a fiber scrim. In still another aspect, the invention provides an adsorbent media including a physisorbent. In this aspect, the physisorbent is preferably selected from the group consisting of activated carbon; activated alumina; molecular sieves; silica gel and combinations thereof. In yet another aspect, the invention provides an adsorbent media comprises a chemisorbent. In this aspect, the chemisorbent is preferably a material impregnated with at least one material selected from the group consisting of potassium permanganate, calcium carbonate, potassium carbonate, potassium hydroxide, sodium carbonate and calcium sulfate; and combinations thereof. In a further aspect, the invention provides an adsorbent media having at least one side surface wherein at least one flow layer is adjacent to a side surface, the top surface, or the bottom surface of the adsorbent media. In another aspect, the invention provides a flow layer including two or more grooves. In this aspect, the grooves may be parallel, form a radial pattern or intersect. In still another aspect, the invention provides an adsorbent breather assembly in which the flow layer is porous. In yet another aspect, the invention provides an adsorbent breather assembly in which the flow layer comprises a discontinuous pattern of adhesive. In a still further aspect, the invention provides an adsorbent breather assembly in which the flow layer is about 0.5 mils to about 50 mils thick. In another aspect, the invention provides an adsorbent breather assembly in which the flow layer is about 10 mils to about 25 mils thick. In yet another aspect, the invention provides an adsorbent breather assembly in which the flow layer is about 10 mils to about 20 mils thick. In still another aspect, the invention provides an adsorbent breather assembly in which the flow layer comprises an impermeable material having grooves on at least one surface In another aspect, the invention provides an adsorbent breather assembly wherein the adsorbent media comprises two or more layers. In yet another aspect, the invention provides an adsorbent breather assembly in which the adsorbent includes a first layer having at least one flow layer and a second adsorbent layer adjacent to the flow layer of the first adsorbent layer. In this aspect another flow layer may be adjacent to the second adsorbent layer. BRIEF DESCRIPTION OF THE DRAWINGS The operation of the present invention should become apparent from the following description when considered in conjunction with the following drawings, in which: FIG. 1 is a top view of an embodiment of the filter unit of the present invention as it would be located on a drive housing; FIG. 2 is a side cross-sectional view of an embodiment of the filter unit of the present invention, as it would appear on the enclosure housing; FIG. 3 is a side cross-sectional view of a computer hard disk drive showing an embodiment of the filter unit of the present invention installed therein; FIGS. 4A and 4B are side cross-sectional and top views, respectively, of an embodiment of the filter unit of the present invention having flow layers adjacent to the top and bottom surfaces of the adsorbent; FIGS. 5A and 5B are side cross-sectional and top views, respectively, of another embodiment of the filter unit of the present invention having flow layers adjacent to the side and bottom surface of the adsorbent layer; FIGS. 6A and 6B are side cross-sectional and top views, respectively, of another embodiment of the filter unit of the present invention having flow layers adjacent to the top, bottom, and sides of the adsorbent layer; FIGS. 7-10 are side cross-sectional views of flow layers according to embodiments of the invention showing groove patterns on the flow layers; FIGS. 11A and 11B are side cross-sectional and top views respectively of another embodiment of the present invention including a diffusion tube within the construction of the filter element. FIG. 12 is a side cross-sectional view of another embodiment of the present invention showing the filter element in an outside mount configuration. FIGS. 13 and 13B are side cross-sectional and top views respectively of another embodiment of the present invention showing the filter in an outside mount configuration with a diffusion tube within the construction of the filter element; FIG. 14 is a side cross-sectional view of another embodiment including a recirculation filter included within the filter construction; FIG. 15 is a side cross sectional view of another embodiment with a filler or gasket around the filter that is countersunk into the drive baseplate such that the assembled filter and gasket are level with the drive baseplate. FIGS. 16A and 16B are side cross-sectional and top views of another embodiment where a top perimeter groove in the adsorbent is used along with a bottom flow layer. FIGS. 17A and 17B are side cross-sectional and top views of another embodiment in which the adsorbent comprises multiple layers of adsorbent material with a flow layer disposed between the two layers as well as on the top of the first or top adsorbent layer and on the bottom of the second or bottom adsorbent layer. DETAILED DESCRIPTION The adsorbent breather filters of the present invention include an adsorbent disposed on a mounting adhesive layer, and a filter layer covering the adsorbent. A flow layer adjacent to at least one of the surfaces of the adsorbent improves filter performance. The filter layer encapsulates the adsorbent and the flow layer between the filter media layer and the mounting adhesive layer. Preferably, the mounting adhesive layer also attaches the filter to the drive. The present invention consolidates filtration functions which were often performed by two, three, or more filters into a single filter that functions well, is easy to install, is clean and cleanable. Moreover, as one of skill in the art will readily appreciate, further components, such as a gasket or gasket(s) or vibration dampening materials, can be included to further reduce the number of components required for final assembly. Common to all embodiments of the invention is the highly dense adsorbent media combined with at least one flow layer to allow good airflow while maintaining maximum adsorbent capacity and good adsorbent performance. The filter may comprise a layer or layers of adhesive to attach the filter to the proper location on the interior or exterior of the drive enclosure wall. The filter may optionally cover an inlet diffusion tube or channel in the drive housing, or the filter may fully contain a diffusion tube. A layer of filter media to filter the incoming air of particles is provided in substantially laminar relation to the adhesive. An optional layer or layers of filter media can be provided to filter recirculating air. A layer or layers of adsorbent media is provided to filter one or both of the incoming and recirculating air streams of vaporous contaminants. Appropriate partitioning of the filter is provided to permit flow channels for inlet air and for recirculating air without the possibility of allowing unfiltered inlet air through the filter. The adsorbent may comprise one or more layers of 100% adsorbent materials, such as granular activated carbon, or may be a filled product matrix such as a scaffold of porous polymeric material compounded with adsorbents that fill the void spaces. Other possibilities include adsorbent impregnated nonwovens or adsorbent beads on a scrim where the non-woven or scrim may be cellulose or polymeric and may include latex or other binders as well as porous castings or tablets of adsorbents and fillers that are polymeric or ceramic. The adsorbent can also be a mixture of different types of adsorbents. Suitable adsorbents include: physisorbers (e.g. silica gel, activated carbon, activated alumina, molecular sieves, etc.); chemisorbers (e.g. potassium permanganate, potassium carbonate, potassium hydroxide, potassium iodide, calcium carbonate, calcium sulfate, sodium carbonate, sodium hydroxide, calcium hydroxide, powdered metals or other reactants for scavenging gas phase contaminants); as well as mixtures of these materials. For some applications, it may be desirable to employ multiple layers of adsorbent materials, with each layer containing different adsorbents to selectively remove different contaminants as they pass through the filter or as they may be exposed from inside the enclosure. Preferably, the adsorbent utilizes an adsorbent-filled PTFE membrane wherein adsorbent is entrapped within the reticular PTFE structure as taught by U.S. Pat. No. 4,985,296 issued to Mortimer, Jr. and specifically incorporated herein by reference. As used herein, a membrane includes thin sheets, tapes or films of polymeric material. Most preferably, particles are packed in a multi-modal (e.g. bi-modal or tri-modal) manner with particles of different sizes interspersed around one another to fill as much of the available void space between particles as is possible, so as to maximize the amount of active material contained in the core. This technique also allows a number of sorbents to be filled into a single layer. The core can then be compressed or layered and compressed to attempt to maximize adsorbent loading and density. Previously air flow was required through the adsorbent and expanding of the material was required to allow for airflow, but with this invention, high density adsorbent materials are combined with flow layers on one or more surfaces of the adsorbent to allow for good airflow, good adsorbent performance and maximum adsorbent loading and density. Another preferred embodiment of the adsorbent layer that can be used in the present invention is discussed in detail in Japanese Laid-Open Patent Application (Kokai) Number 4-323007. In one aspect, the invention includes at least one flow layer adjacent to the adsorbent. As used herein, a “flow layer” is intended to mean a material that allows the passage of gas through pores or interstices. A flow layer may be constructed of any porous material. Alternatively, a flow layer may be constructed of non-porous materials shaped or formed to provide interstices for gas flow channels within or adjacent to the flow layer. The gas flow channels may be random or of any configuration or pattern. For example, the pattern may be linear; consisting of either parallel or intersecting grooves in the surface of the flow layer, and may also be radial and may be centered about an inlet port for a drive. Alternately, a flow layer may comprise a layer of patterned adhesive. As used herein, a “patterned adhesive” is a layer of adhesive that is discontinuous, or has gaps within the layer exposing the underlying substrate. Such a discontinuous layer may be in the form of patterned adhesive lines, which are either parallel or intersecting. In another aspect, the patterned adhesive may be in the form of a matrix of adhesive dots spaced at random or regular intervals. Alternatively, a matrix consisting of adhesive dots could be applied to make a crosshatched pattern. The patterned adhesive may be zone or strip coated onto a carrier. In yet another alternative, a zone or strip coat of adhesive is applied to the filter membrane or to the adsorbent. The flow layers allow for improved airflow over the adsorbent material surface, which results in greater filtration and adsorbent performance. Due to improved surface airflow, it is not necessary that the air flow through the adsorbent media. Using flow layers reduces the pressure drop across the filter. Accordingly, the flow layers, and the surface flow paths provided thereby, permit high-density adsorbent materials to be used. In the embodiments described and illustrated herein, the adhesive layer is typically a mounting adhesive layer for mounting the filter to the enclosure wall. However, the adhesive layer may have different constructions. It can be a single layer of transferable adhesive, a single sided adhesive coated onto a carrier or substrate such as polyester or polyethylene or a double-sided adhesive coated onto a carrier or substrate as described within the illustrations. The selection of an adhesive is not critical. However, the adhesive must have a high enough peel strength to withstand application use and meet any use specifications that may exist such as high temperature, solvent resistance, FDA approval, repositionable, or low outgassing specifications. Selection of an appropriate adhesive is understood by one of skill in the art. A typical low outgassing specification is to pass ASTM E-595-84 specification of less than 1% total mass loss and 0.1% collected volatile condensable material. A preferred embodiment utilizes one layer of 0.001″ (0.0025 cm) thick permanent acrylic pressure sensitive adhesive applied to the outer side of the film and a second layer of double-sided permanent acrylic pressure sensitive adhesive 0.004″ (0.010 cm) thick for the inner most adhesive which contacts the filter material and adsorbent. This adhesive has medium to high peel strengths in excess of 20 ounces/inch as measured by PSTC #1 (FTMI) and passes outgassing ASTM E-595-84 specification. A commercially available transfer adhesive is [3M 9457] and a commercially available double-sided adhesive is [3M 415] which both employ an A-40 acrylic adhesive all commercially available from Minnesota Mining Manufacturing, Inc. of Minneapolis, Minn. Other adhesives, such as hot melt adhesives, thermoset and thermoplastic adhesives, UV curable adhesives, or other curable adhesives, epoxies and other reactive adhesives, etc. are also suitable. Furthermore, if a diffusion tube is desired, adhesives as described in U.S. Pat. No. 5,417,743, the disclosure of which is hereby incorporated by reference, can be used. For example in many of the examples illustrated above incorporating a diffusion tube, a second adhesive layer is superimposed over the first. This second layer could again be just adhesive, but a single-sided (i.e., adhesive on one side of a carrier or substrate) or double-sided adhesive is preferred for ease in handling and processing. Prior to attachment to the disk drive housing, the exposed adhesive layers may have one or more release liners adhered thereto to protect the adhesive and to facilitate handling of the filters. The release liners would be removed prior to assembly of the filter onto the disk drive enclosure. PTFE membrane filter materials can be used to cover the adsorbent material and act as filtration membranes. One such preferred filter media to encapsulate the adsorbent layer is a layer of expanded PTFE membrane made in accordance to U.S. Pat. No. 4,902,423 issued to Bacino et al. and incorporated herein by reference. This filter media may be structurally supported by a layer of woven, nonwoven, or expanded porous material, such as polyester, polypropylene, polyamide, etc. This filter media has several advantages. It can be made very highly permeable, with resistances to air flow of less than 0.5 mm H 2 O @ 10.5 feet per minute (3.2 meters per minute) and still contain adsorbent particulate within the filter. The particle filtration efficiency of this highly expanded membrane as measured on a TSI 8160 efficiency test rig available from TSI Inc., in Minnesota, is also very good (e.g. in excess of 55% at 0.3 μm) which provides good particle filtration along with the adsorbent containment. A preferred support layer is a Reemay 2014 polyester nonwoven, 1.0 oz/yd 2 available from Reemay, Inc., Old Hickory, Tenn. A second preferred filter media to cover or encapsulate the adsorbent layer is a layer of an electrostatic triboelectret material available in finished filter form from W. L. Gore and Associates, Inc. under the trademark GORE-TRET® recirculation filters. An illustrated example of this would be layer 67 in FIG. 14 . Advantages of this media are that it is very high in efficiency (e.g., in excess of 90% @ 0.3 micron) and also very permeable (e.g., less than 1 mm H 2 O at 10.5 fpm or 3.2 m/min). While this media loses its charge while being washed with deionized water, it immediately regains its efficiency upon drying due to the triboelectric effect of the mix of dissimilar fibers. Other filter materials can also be used. They could be other electrets or other triboelectret materials that yield high efficiencies and low resistances to airflow. They could also be other filter papers or filter membranes such as polypropylene membranes or cast polymeric membranes or some combination of filter materials. Different filter materials with different properties can be used in the different embodiments of the invention wherever filter layers are used and/or optionally used depending upon the required performance needed. An outer protective layer can also be used to add durability to the filter and to contain any protruding fibers from either the triboelectret type filter media or the filter support media for the membrane filter media. Typically, this would be an extruded or expanded plastic material such as polypropylene, polyethylene, polyamide, polyester, etc. A preferred material is a Delnet 0707 expanded polypropylene material available from DelStar Technology, Inc., Middletown, Del. Using PTFE membranes as a filter material over the adsorbent layers imparts a number of additional advantages to this improved filter construction. First, PTFE is hydrophobic. Some adsorbents used in the industry use a water-soluble salt to impregnate a physical adsorbent such as activated carbon to provide a chemical adsorbent with a large active surface area. However, the water-soluble chemi-sorbent salts are removed if the filter is washed. By covering the carbon layer with the PTFE membrane, the final part is waterproof and washable; water can come into contact with the part and not penetrate the adsorbent. Washability is important because ionic contamination is a major concern for corrosion susceptible apparatus such as computer disk drives. Ions of concern, such as chlorine and sulfur dioxide, are readily soluble in water, so washing with deionized water has become routine for many components used within a drive. Also, reworking of drives that initially fail certification is common in the industry and often washing the drive housing is included in reworking. Thus, embodiments utilizing PTFE filter layers to encapsulate the adsorbent allows use of water soluble, salt treated adsorbents and can withstand washing without losing adsorbent effectiveness. And reworking can be done without having to remove the adsorbent filter from the housing. Filters in accordance with the present invention are not only low in particulation, outgassing, and nonvolatile residues, the filters may also be washable. Washing with deionized water to remove surface ionic contamination and particulation improves the filters' suitability for those applications requiring such cleanliness, such as in computer disk drives. The filters may be washed without washing out beneficial treatments such as salts, which remove acid gases from the air streams. This washability is accomplished by using hydrophobic filter materials (along with impermeable layers such as adhesives, etc.) to surround the adsorbent layers. “Hydrophobic” as used in this application means the filter materials have a water (or water with surfactant if one is used) entry pressure sufficient to withstand the conditions of conventional washing steps, such as heating, stirring, ultrasonics, etc. While the PTFE membranes mentioned above are hydrophobic and can be washed, they also have a high vapor transmission rate, which allows contaminants in the air to quickly and easily diffuse through the membranes into the adsorbents. PTFE membranes can also be made with very good filtration efficiencies, which is especially beneficial in the breather filter and adsorbent breather filter applications. An exemplary membrane could be made in accordance with U.S. Pat. No. 3,953,566. Such a membrane can have a filtration efficiency of 99.97% at 0.3 microns sized particles and a permeability or face velocity of 7 feet/minute (3.56 cm/sec) at 0.5 inches (1.27 cm) of water pressure. The membrane is commercially available in finished filter form from W. L. Gore and Associates, Inc. Additionally, PTFE is a non-linting, non-outgassing inert binder that can be used as an adsorbent binder by mechanically entrapping adsorbent particles within the PTFE material. This entrapment effectively reduces dusting of adsorbent material during the manufacture and during the life of the filter. This material can also be made in a relatively thin, highly loaded material as described in U.S. Pat. No. 4,985,296. The PTFE/adsorbent composite can be made in thicknesses from less than 0.001″ to 0.400″ or more. This allows a great deal of flexibility in finished filter thicknesses and adsorbent loading. Additionally, sorbent densities approximating 80-95% of full density are possible with multi-model packing and physical compression, so that maximum adsorbent material can be packed per unit volume. Unlike binders such as acrylics, melted plastic resins, etc., PTFE does not block the adsorbent pores. The present invention provides a compact, clean, low outgassing (i.e., typically less than 20,000 ng/g at 85° C. for four hours), low particulating (i.e., typically less than 50 one hundred micron sized particle per square centimeter when tested with a liquid particle counter), unitary adsorbent breather filter and also, optionally, can be washable, particularly if the filter comprises hydrophobic PTFE membranes. The invention can utilize any suitable adsorbent type and be tailored for preferential performance in filtering of air from both internal and external sources for particles as well as hazardous vapor contaminants. As a single unit, the multi-functional filter minimizes installation time, as compared to the use of several conventional parts to achieve the required filtration and adsorption. The filter can further be combined with an optional diffusion tube to improve the performance of the breather component. The filter can still further be combined with a gasket to provide a means of sealing the disk drive. The multi-functional filters of the present invention can be used in filters where air is driven by normal convection, by diffusion means, by an auxiliary fan, or some combination thereof. A diffusion tube can be included with the adsorbent breather filter as described in U.S. Pat. No. 5,417,743 by Dauber and U.S. Pat. No. 5,997,614 by Tuma et. al. Diffusion tubes provide additional protection against vaporous contaminants (including moisture) entering the drive through the breather opening by providing a diffusion barrier in the form of the diffusion tube which creates a tortuous or a longer path for contaminants to diffuse through before entering the drive enclosure. Diffusion tubes reduce the number of contaminants reaching the interior of the enclosure (and/or the adsorbent depending on the location of the filter) and increase the humidity time constants or time required to reach humidity equilibrium with the environment. As used herein, for convenience, the term “diffusion tube” may refer to either a conventional tortuous path or it may refer to a non-tortuous cavity into which incoming air passes before entering the filter. The invention may be better understood with reference to the Figures, in which like parts have like numbering. Referring to FIG. 1 , there is shown a top perspective view of one embodiment of the multi-functional filter assembly 40 of the present invention as it would appear looking down on the filter mounted to an interior wall of a drive enclosure housing 41 . FIG. 2 shows a side cross-sectional view of another embodiment of a filter assembly 40 of the present invention as it would appear mounted on a disk drive enclosure housing 41 . The air stream path is indicated as 21 . The mounting adhesive layer 42 mounts the filter assembly 40 to the housing 41 and has a hole or opening 45 to allow the air to flow into and through the mounting adhesive layer 42 . Layer 44 is the filter media. Layer 43 is a single layer adsorbent. A second optional filter media layer 26 is located such that the filter media encapsulates the adsorbent 43 . Such a construction is desirable for adsorbents that may particulate because the filter media prevents such particulation from entering the drive during installation. Moreover, if the filter media is hydrophobic, the filter is washable. A pattern of adhesive strips is coated onto the adsorbent top surface as shown in layer 28 . A patten of adhesive strips on bottom surface is shown as layer 29 . FIG. 3 shows additional features of a computer hard disk drive into which the filter assembly of FIG. 1 has been incorporated. Additional components typically present within a drive are shown, such as the rotating magnetic recording disks 11 , the read/write heads 12 and the armatures 13 for moving the heads. The rotating disks 11 are the driving force for circulating, or recirculating, air within the disk drive. FIGS. 4A and 4B show a side cross-sectional and top view respectively of one embodiment of the invention having flow layers adjacent to multiple surfaces of the adsorbent media, here shown as adjacent to the top and bottom surfaces. As shown in FIG. 4A , the filter 40 comprises a layer of mounting adhesive 42 with a hole 45 cut through it. A flow layer 46 is disposed between the mounting adhesive layer 42 and the bottom surface of adsorbent layer 43 . A second flow layer 47 is adjacent to the top surface of the adsorbent, between the adsorbent layer 43 and the filtration layer 44 . As used herein, the bottom refers to the side closest to or facing the opening. The top refers to the surface opposite the bottom. Filtration layer 44 encapsulates the adsorbent and the flow layer between the mounting adhesive 42 and the filtration layer 44 . The filtration layer 44 is adhered to the mounting adhesive layer 42 . It should be apparent to one of skill in the art that the mounting adhesive may comprise a pressure sensitive adhesive layer, a double-sided adhesive tape on a backer material or multiple sided adhesive on multiple backers, depending on the desired construction of the filter. The mounting adhesive may also comprise a heat sensitive or UV or other curable adhesive layer. The mounting adhesive may also be a thermoplastic or thermoset material that will be able to mount to the enclosure surface. The hole 45 is aligned with a hole in the enclosure, such that air will enter the drive housing through the enclosure hole and the hole 45 in the mounting adhesive layer 42 . The air will then pass along or through the flow layer 46 , and either pass through the filter layer 44 or along the sides of the adsorbent media and then further along or through the flow layer 47 adjacent to the top surface of the adsorbent media, before passing through the filter media 44 . FIGS. 5A and 5B show side cross-sectional and top view respectively, of another embodiment of the filter assembly 40 where there are flow layers adjacent to the bottom and side surfaces of the adsorbent. The flow layers here are flow layers 46 adjacent to the bottom surface of the adsorbent layer 43 and flow layer 48 around the sides of the adsorbent layer 43 . FIGS. 6A and 6B show side cross-sectional and top views respectively of another embodiment with flow layers adjacent to the top, bottom, and side surfaces of the adsorbent. Again the layers are defined similarly to the way they were defined for FIGS. 4A and 4B and 5 A and 5 B respectively. FIGS. 7 , 8 , 9 , and 10 show a few of the possible patterns of flow layers useful in embodiments where the flow layer comprises a non-porous material having interstices or grooves therein to improve filter airflow. These by no means exhaust the possibilities, but are shown for illustrative purposes. FIGS. 11A and 11B show a side cross-sectional view and a top view of another embodiment of the present invention where a diffusion tube is included with the adsorbent breather filter 40 . Layers 30 , 31 , and 32 are a double-sided adhesive where layers 30 and 32 are adhesive coated onto the carrier layer 31 . The adhesive layers 30 , 31 , and 32 have a hole or slot 35 cut through them that will be aligned at one end with a hole 36 in the disk drive enclosure wall 41 . Layers 33 and 34 are single sided adhesive layers with layer 34 being the adhesive on a carrier layer 33 and is superimposed over layer 32 with hole 37 cut through it and superimposed over the end portion of hole or slot 35 which is opposite the end that is aligned over hole 36 . Adsorbent layer 43 in this case has a flow layer 47 adjacent to the top surface, and a flow layer 46 adjacent to the bottom surface. The adsorbent layer 43 is superimposed over hole 37 and extends further over part of layer 34 . Layer 44 is a filter layer, such as of a high efficiency membrane for good breather filtration efficiency, which covers adsorbent layer 43 and is adhered to adhesive layer 34 FIG. 12 is a side cross-sectional view of another embodiment of the present invention that is an outside mount version of the invention. Here filter 40 mounts on the outside of the enclosure wall 41 instead of the inside as previously shown. Layer 42 is a mounting adhesive layer that may be only adhesive or a double sided adhesive layer as previously detailed that has hole 56 cut through it and is placed over the vent hole 45 of the enclosure wall 41 . Filter layer 53 is against the adhesive layer 42 and may be laminated or adhered to the adsorbent layer 43 and filters incoming air of particulates, can perform as a flow layer, and contains the adsorbent particles from entering the drive. Adsorbent layer 43 is shown with a flow layer 57 adjacent to its top surface. Layer 52 is an air impermeable layer that protects the carbon from the environment and contains the carbon to remove contaminates from the air within the drive and the air passing through hole 55 in the impermeable layer 52 . The hole 55 may be offset from holes 45 and 56 , but need not be. The outside mount filter is shown here as mounting on a flush enclosure wall 41 , but the enclosure wall 41 could also be recessed and the filter mounted such that when installed, the filter outside surface may be flush with the outside wall surface. In such cases, it may be possible to have the impermeable layer 52 optionally mounted on the outer wall surface instead of the filter itself. Furthermore optional filter layers may be inserted such as between the adsorbent layer 43 and the impermeable layer 52 if desired placement of the layers or by use of lamination of layers together or by using additional adhesive or adhesive layers. FIGS. 13A and 13B are side cross-sectional and top views respectively of an additional embodiment of the present invention where the filter is mounted on the outside of the enclosure wall similar to the FIG. 12 embodiment, but also has built in diffusion tube characteristics similar to the FIGS. 11A and 11B embodiments. Filter 40 is applied to the outside or enclosure surface 41 . Mounting adhesive layer 42 again can be a layer of adhesive or a double sided adhesive layer with hole 56 cut in it and applied such that hole 56 aligns with hole 45 in the enclosure wall 41 . Filter layer 53 is against the mounting adhesive layer 42 to filter the incoming air of particulates, perform as a flow layer, and contain carbon particles from the adsorbent layer 43 , which in this illustration has flow layer 47 adjacent to its top surface. Layer 58 is an impermeable layer over the adsorbent layer 43 . It could optionally have adhesive on either side for aiding assembly of the filter. For instance if it has adhesive on the side facing mounting adhesive layer 42 , then mounting adhesive layer 42 could have optionally been a single sided adhesive. Hole 64 is cut through the impermeable layer 58 to allow airflow to pass from the exterior to the carbon and eventually into the enclosure. Layers 59 , 60 , and 61 are a double-sided adhesive with layers 59 and 61 being adhesive on both sides of the carrier 60 . Hole or slotted hole 62 is cut through layers 59 , 60 , and 61 and aligns at one end with hole 64 through the impermeable layer 58 . Impermeable layer 57 then is placed on layer 61 . Optionally layer 61 could be an adhesive layer on the impermeable layer 57 and layers 59 and 60 could have been a single sided adhesive, again showing flexibility of construction possibilities. Hole or slot 62 aligns at one end with hole 63 cut in the impermeable layer 57 and at the opposite end with hole 64 . FIG. 14 is a side cross-sectional view of an alternative embodiment of the present invention with a recirculation filter included as part of the construction. The construction of this illustration is the same as was used in FIGS. 4 and 4A except that another filter layer 67 is placed over filter layer 44 . Filter layer 67 is typically a more open layer to allow more airflow through the layer to have increased performance to clean air passing through it of particles. As the disks inside a drive spin, air is recirculated around inside the drive and such open filtration layers are typically used as a recirculation filter to clean the inside of the enclosure of particles. Optionally layers 44 and 67 could be combined into a single layer that is both open enough to allow recirculating air to flow through it to clean it of particles and efficient enough to clean the incoming air sufficiently of particles. One possible media of construction for layer 67 is an electret material such as that made by 3M company. FIG. 15 is a side cross-sectional view of another embodiment of the present invention which is similar to that shown in FIGS. 4 and 4A , where now a filler or gasket 81 is placed over the filter that is countersunk into the enclosure wall such that the resultant filter and gasket are flush mounted into the enclosure. This can be of value to minimize the filter's disturbance to airflow and to minimize the space the filter takes up inside the enclosure. Both these can be important particularly for high revolution per minute Disk Drives and for very small Disk Drives. FIGS. 16A and 16B are cross-sectional and top views respectively of another embodiment of the invention similar to FIGS. 4A and 4B , except where the adsorbent layer 43 has a perimeter top groove. FIGS. 17A and 17B are cross-sectional and top views respectively of a further embodiment of the invention again similar to FIGS. 4A and 4B where the adsorbent layer 43 is replaced by multiple adsorbent layers, in this case layers 82 and 83 with a flow layer 49 disposed between them. It should be clear to one skilled in the art that these illustrations are by no means exhaustive in how such a filter can be assembled and how combinations of the various filter enhancements can be combined in the filter construction. Different materials can also be used as the impermeable layer shown in FIGS. 12 and 13 . Polymer layers such as polyester, polypropylene or the like can be used as well as metallized polymer layers such as a metallized polyester. A preferred impermeable layer is a layer of thin aluminum. More preferably the impermeable layer is dead soft aluminum because it is impermeable, formable, and provides a good electromagnetic shield. For example, a 0.003″ thick dead soft aluminum layer as sold by ALL FOILS Brooklyn Heights, Ohio, is appropriate for use in the invention. TEST PROCEDURES Airflow Test: Airflow was tested by making a fixture where the filter of the invention could be adhered over a hole in the fixture. The size of the hole in the fixture was 0.08″ (0.203 cm) in diameter. Air was delivered to the back side of the filter through a port (to allow air to flow through the hole in the mounting adhesive and through the filter). Another port on the fixture was placed to measure back pressure or the pressure required to flow a given volume of air through the filter. The filters were all tested at an airflow rate of 30 ml/min. Various filter constructions could then be tested and compared for airflow Without intending to limit the scope of the present invention, the following examples illustrate how the present invention may be made and used. EXAMPLES Samples were made to test for resistance to airflow. The samples were all made using a commercially available double-sided acrylic adhesive from Adhesive's Research in Glenn Rock, Pa. The adsorbent was an adsorbent filled PTFE previously mentioned and made in accordance to U.S. Pat. No. 4,985,296. Some were compressed to form grooves in the adsorbent. Each adsorbent contained approximately 240 mg of activated carbon and was placed on a layer of adhesive. The filter layer was a 0.2 micron rated PTFE membrane as made and supplied in finished filters by W. L. Gore and Associates, Newark Del. The filter layer covered the adsorbent and was bonded to the adhesive layer at the perimeter of the adsorbent. The following samples were made: Comparative Example 1 was constructed with grooves in the adsorbent on only the bottom side of the adsorbent; Inventive Example 1 had a flow layer consisting of a 30 gm/m 2 electret on only the bottom side of the adsorbent (without grooves); Inventive Example 2 had a flow layer made from strips of the double-sided adhesive on the bottom side of the adsorbent (without grooves) only. Additional samples were made in which a layer of the 30 gm/m 2 electret flow layer was added to the top of the adsorbent layer of each of the above constructions such that Inventive Example 3 had an adsorbent with grooves on the bottom and the electret flow layer on top; Inventive Example 4 had electret flow layers on the top and bottom of the adsorbent (without grooves) and Inventive Example 5 had strips of the double-sided adhesive on the bottom side of the adsorbent (without grooves) and an electret flow layer on top. Finally, Inventive Example 6 was constructed with a flow layers made from strips of the double-sided adhesive on both the top and bottom of the adsorbent (without grooves) media. The examples were then compared for airflow performance. The filters were placed on the airflow test fixture and tested in accordance with the procedures previously outlined above. The results are contained in Table 1. TABLE 1 Airflow Resistance Example Top Surface Bottom Surface (mm H 2 O) Comparative No Layer Grooves 26.1 Example 1 Inventive Example 1 No Layer Electret 9.5 Flow Layer Inventive Example 2 No Layer Adhesive Strips 26.7 Inventive Example 3 Electret Flow Layer Grooves 4.0 Inventive Example 4 Electret Flow Layer Electret 7.4 Flow Layer Inventive Example 5 Electret Flow Layer Adhesive Strips 2.4 Inventive Example 6 Adhesive Strips Adhesive Strips 17.6 It is clear that the flow layers significantly reduced the pressure required to force the air through the filters, thereby enhancing their performance. While particular embodiments of the present invention have been illustrated and described herein, the present invention should not be limited to such illustrations and descriptions. It should be apparent that changes and modifications may be incorporated and embodied as part of the present invention within the scope of the following claims:
The invention relates to a device for filtering contaminants, such as particulates and vapor phase contaminants, from a confined environment such as electronic or optical devices susceptible to contamination (e.g. computer disk drives) by improving performance and possibly incorporating multiple filtration functions into a unitary filter. The filter includes flow layers which improve filter performance. Filtration functions include a passive adsorbent assembly and can include a combination of inlet, or breather filter and adsorbent filter. Moreover, recirculation filter, diffusion tube and outside mount functions can be added to the filter depending on desired functionality within the enclosure.
1
TECHNICAL FIELD [0001] This invention relates to a ribbon curling machine and more particularly to both a hand operated ribbon curling machine and an automatic ribbon curling machine for producing a multiple curled ribbon decorative product where the ribbons overlie each other and are attached together. In some embodiments the curled ribbons are attached to a self sticking backing card or a bow or a display holding card or the like. BACKGROUND OF THE INVENTION [0002] As is known to those skilled in this technology, there are sundry ways in which to curl ribbon of the type that are typically used to decorate packages, flowers/cookie baskets and the like. One of the more arcane methods of curling is by sliding the ribbon over a knife-edge or any other object where the ribbon slides over a friction surface. For example the simple operation of sliding the ribbon over the edge of ordinary pair of scissors causes the ribbon, be it paper or plastic, to curl. This obviously has limitations, such as being slow, typically done for a single ribbon, and in the more common usage the practice was to curl the end portions of a typical decorative bow. Other types of curling has been done by hand-held curling tools as those described In U.S. Pat. Nos. 5,400,452 granted on Mar. 28, 1995; 5,564,145 granted on Oct. 25, 1996; 5,407,417 granted on Apr. 18, 1995 to Fredric Goldstein, one of the joint inventors of this patent application. Obviously, like the scissors described above, the curling tools disclosed in the immediately aforementioned patents all would require tedious curling and assembly of the curled ribbon strands. [0003] In more recent years, the curling of the ribbon has become automated where a drawing apparatus draws the ribbon to be in frictional engagement with an edge to impart a curl to the ribbon and stripping mechanism that permits the mass production of the curled ribbon which can then be utilized for different types of applications. Examples of this type of mass produced curled ribbon is disclosed in U.S. Pat. Nos. 5,518,492 granted on May 21, 1996, 5,711,752 granted on Jan. 27, 1998 and 5,916,081 granted on Jun. 29, 1999 to Fredric Goldstein, a co-inventor of this patent application. [0004] Also, we are aware of other machines that has the ability of making a curled product that has certain similarities to the end product of this invention and is made by an entirely different method. In one instance, a reciprocal sliding mechanism includes a clamp that holds a ribbon while it is drawn over a stapling device. The ribbon is laid over itself to form a stack of curled ribbons and a stapling device staples the ribbon to a backing card and the cycle is repeated. [0005] This invention is primarily concerned with the curled ribbon that is packaged in one or a number of configurations including the configuration as shown in FIG. 1 of this patent application (curly ribbon). As noted therein, this curled ribbon ribbon product has four (4) curled ribbons 2 each of which are stapled in the center via staple 4 . This makes eight (8) strands of curled ribbons 3 emanating from staple 4 . Obviously, when a given length of ribbon is attached intermediate the ends of the ribbon by a staple, the portions of the ribbon emanating from the staple forms two (2) strands. In this end curly ribbon product card 5 and ribbons 2 are stapled together. The card which is designed to hang in a display rack may include one surface (not shown) coated with a glue and a paper cover that is removable to uncover the glued surface for sticking to a package and the front surface may include indicia, such as a logo, price, etc. Obviously, in other embodiments the card may be replaced by or made complementary to other devices or objects such as a bow, ribbon, string etc. It obviously should be understood that the FIG. 1 end product is simply one example of an end product of a curly ribbon product. The end product could include as many strands as desired, and it is typical that more than eight (8) strands are formed to make-up the end product. [0006] In one embodiment of this invention, the apparatus for making this product is portable and hand-operated and in an other embodiment of this invention, the product is automatically produced. It will be appreciated that in both embodiments, the ribbon is wrapped around a drum or rotor as it is rotated about an axis either by hand or a motor and that at discreet locations on the drum are provided mechanism for clamping the ribbons onto the drum, stapling the ribbons and card together and cutting the ribbons in another appropriate location. Obviously, the curled ribbon for some decorative purposes are affixed at an intermediate portion and for others they are affixed at the end. [0007] In one preferred embodiment of this invention, a hand operated drum, reel or disk (hereinafter referred to as a drum) mounted for rotation and includes a handle attached to the drum for causing the rotation. This embodiment also includes a number of posts for holding a number of spools of ribbon, an equal number of guide posts for each of the spools, an equal number of curling clamps where the ribbon is placed in frictional engagement or contact to impart the curl thereto and a single guide post where all the ribbons are accumulated in such a manner that a portion of the ribbon is laid over other portions to form a stack to allow clamping with a single clamp. The drum includes stations to hold the combined ribbons with the use of an alligator clamp, and predetermined stations, one to staple the ribbons together and another to cut the ribbons. A card holder mechanism may be employed at the stapling station where the ribbons and card are simultaneously stapled together. [0008] In another embodiment of this invention, an automated machine mass produces the entire package automatically once the machine is initially threaded. In this embodiment and according to this invention, a clamping mechanism including a pair of jaws judiciously clamps the then curled ribbon to the drum after being curled, the clamp releases the processed ribbon once the drum grasps the ribbons and sequentially re-clamps the next to be processed ribbons to continuously and cyclically produce an entire finished product. Also in accordance with this invention, this automated machine judiciously staples and judiciously cuts the curled ribbons in the proper sequence to produce the end product. [0009] The advantages of utilizing a drum as taught by this invention and without limitation are as follows: [0010] 1) the drum provides a compact drive system, more compact than heretofore known systems, making it possible to have a machine which requires minimal space, and in the portable unit, it can fit on an ordinary kitchen table or the like; [0011] 2) the strands are inherently stacked together in the process of being pulled, unlike sets of wheels which would have to guide the 12 strands, for example, upon each other, which is critical when stapling or attaching the ribbon strands to a card; [0012] 3) the drum obviates the need of sets of wheel or roller drive systems and the necessity of synchronizing the wheels and rollers in these types of systems and avoids the potential of “looping”; [0013] 4) the drum, obviously, can increase the number of strands simply by increasing the number of revolutions in a cycle; [0014] 5) because the ribbon wraps around itself on the drum the ribbon eventually secures itself to the drum and the clamp for originally clamping ribbon to the drum is released. This reduces the drag on the drum reduces as the rotation continues. This obviates the problems of adverse release and tearing of the ribbon in heretofore know systems. Also, the drum inherently requires less power in the drum and clamp to operate than these heretofore known system; and [0015] 6. the system using the drum always ends in the starting position for the next set of strands avoiding the necessity of repositioning the mechanism to begin the process. [0016] In another aspect of this invention, the amount of curl can be controlled by selecting the proper discharge angle that the ribbon makes relative to the surface where the curl is imparted. Typically, the more acute the angle and hence the amount of drag or friction imparted to the ribbon as it is makes contact with the member imparting the drag or friction, the greater the degree of curl in the ribbon. This is the case no matter what the material the ribbon takes. This feature significantly allows the user to decide the overall size and shape of the curled ribbon product, whereby acute angles provides a more compact curled bow while lesser acute angles provides larger more flowing curls. When producing the curled ribbon product by an automated machine the curling device of this invention allows for consistency and flexibility in production. SUMMARY OF THE INVENTION [0017] An object of this invention is to fabricate a curled ribbon end product either manually or automatically by winding a plurality of ribbons around a rotating body and simultaneously imparting a curl thereto and then affixing the ribbons to another member and cutting the ribbon at different locations on the rotating body. [0018] A feature of this invention is to provide a hand operated machine for making curled ribbons and attaching a plurality of ribbons taken from spools of ribbons to a clip or bobbin that is inserted into a rotatable drum that is rotated about an axis as by a handle mounted on the drum to draw the ribbons over a curling mechanism and which drum includes different stations for stapling the ribbons to each other and/or a card and for cutting the curled stapled ribbons. [0019] Another feature of this invention is to provide a machine for automatically curling ribbons, attaching the curled ribbons to the drum of the machine, stapling the curled ribbons together at one station of the drum and cutting the ribbons at another station of the drum for producing a decorative piece. It will be appreciated that unless the ribbon upstream of the cutting or severing device is clamped prior to cutting, the ribbon will become disengaged from the drum and disrupt the cycle. [0020] Another feature of this invention is to provide a curling device for imparting a curl to the ribbon that includes mechanism for changing the exit angle that the ribbon makes with the curling mechanism to control the curl characteristics of the ribbon. [0021] Another feature of this invention is to provide a clamp that comprises automated fingers or jaws that are Controllable to temporally clamp, release and re-clamp a plurality of ribbons wound around a rotating drum. [0022] Another feature of this invention is to provide an automatic machine for mass producing decorative curled ribbons by curling each of a number of ribbons and then combining and processing the combined ribbons through a number of sequential operations including the steps of winding the plurality of ribbons around a drum after being curled, affixing the curled ribbons to a card having a glued backing with the use of an automatic card feeding and stapling mechanism, an anvil, separately cutting the assembled card and curled ribbons that are attached to the card and releasing the assembled unit from the machine. [0023] Another object of this invention is the method for producing a decorative multi-colored curled ribbon end product from a continuous supply of different colored uncurled ribbons including the steps of combining the different colored ribbons, stapling and cutting thereof. [0024] Another feature of this invention is to provide a method that cyclically produces a curled ribbon product by the steps of providing a rotating drum, a clamp for clamping a plurality of ribbons which may be of different colors to a the drum until the ribbons are self-supported to the drum and then releasing the clamp from the ribbons, re-clamping the plurality of ribbons, affixing the ribbons together and then cutting the affixed ribbons in one cycle so as to provide a continuous process for mass producing the end product without the necessity of manually feeding the machine after the initial feed. [0025] A still further object of this invention is to teach a system for making curled ribbon product that is characterized as being simple and inexpensive to use and manufacture as well as affording the following advantages: [0026] 1) a compact drive system, more compact than heretofore known systems is attained, making it possible to have a machine which requires minimal space, and in the portable unit, it can fit on an ordinary kitchen table or the like; [0027] 2) the strands are inherently stacked together in the process of being pulled, unlike sets of wheels which would have to guide the 12 strands, for example, upon each other, which is critical when stapling or attaching the ribbon strands to a card; [0028] 3) it obviates the need of sets of wheel or roller drive systems and the necessity of synchronizing the wheels and rollers in these types of systems and avoids the potential of “looping”; [0029] 4) it increases the number of strands simply by increasing the number of revolutions in a cycle; [0030] 5) because the ribbon wraps around itself on the drum the ribbon eventually secures itself to the drum and the clamp for originally clamping ribbon to the drum is released. This reduces the drag on the drum reduces as the rotation continue This obviates the problems of adverse release and tearing of the ribbon in heretofore know systems. Also, the drum inherently requires less power in the drum and clamp to operate than these heretofore known system; and [0031] 6. the system always ends in the starting position for the next set of strands avoiding the necessity of repositioning the mechanism to begin the process. [0032] The foregoing and other features of the present invention will become more apparent from the following description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0033] [0033]FIG. 1 is a perspective view showing one version of the decorative curled ribbon after being processed; [0034] [0034]FIG. 2 is a perspective view of the hand operated curl making machine of this invention; [0035] [0035]FIG. 2A is a schematic view of the embodiment depicted in FIG. 2; [0036] [0036]FIG. 3 is a view in perspective and schematic illustrating a portion of the automated machine of this invention; [0037] [0037]FIG. 4 is a schematic illustration of the various stations on the drum and the actuation mechanisms associated with each of the stations for the automated machine of this invention; [0038] [0038]FIG. 5 is an isometric exploded view illustrating the details of the curling mechanism of this invention; [0039] [0039]FIG. 6 is a side view and schematic illustration of the curling mechanism of FIG. 5 illustrating the exit angle that the ribbon makes relative to the curling mechanism that can be changed to change the curling characteristic of the ribbon; [0040] [0040]FIG. 7 is a partial view in perspective illustrating the clamping and cutting stations of this invention. [0041] [0041]FIG. 8 a is a schematic illustration of the various stations on the drum and the actuation mechanisms associated with each of the stations for the automated machine of this invention where the drum is at a given location for one of the functions of the cycle; [0042] [0042]FIG. 8 b is a elevated view of the a portion of the drum at one of the stations illustrating the position of the clamp and ribbons at the location of FIG. 8 a; [0043] [0043]FIG. 9 a is identical to FIG. 8 a illustrating a different location of the drum at a different function of the machine during the cycle of operation; [0044] [0044]FIG. 9 b is identical to FIG. 8 b illustrating the a different position of the clamp and ribbon at the location of FIG. 9 a; [0045] [0045]FIG. 10 a is identical to FIG. 9 a illustrating a different location of the drum at a different function of the machine during the cycle of operation; [0046] [0046]FIG. 10 b is identical to FIG. 9 b illustrating the a different position of the clamp and ribbon at the location of FIG. 10 a; [0047] [0047]FIG. 11 a is identical to FIG. 10 a illustrating a different location of the drum at a different function of the machine during the cycle of operation; [0048] [0048]FIG. 11 b is identical to FIG. 10 b illustrating the a different position of the clamp and ribbon at the location of FIG. 10 a; [0049] [0049]FIG. 12 a is a partial view partly in section, partly in elevation and partly in schematic illustrating the anvil and stapling mechanism of this invention in the deployed position; [0050] [0050]FIG. 12 b is identical view of FIG. 12 a illustrating the staple and anvil in the non-deployed position; [0051] [0051]FIG. 13 is a plan view of the card feeding mechanism of this invention; [0052] [0052]FIG. 14 is a block diagram showing the various actuators within the drum and the medium for actuating these actuators; and [0053] [0053]FIG. 15 is a block diagram showing the various actuators outside of the drum and the medium for actuating these actuators. [0054] These figures merely serve to further clarify and illustrate the present invention and are not intended to limit the scope thereof DETAILED DESCRIPTION OF THE INVENTION [0055] While the invention in its preferred embodiment utilizes a particularized curling mechanism and stapling card it is be understood as one skilled in this art will recognize that this invention contemplates utilizing any type of curling mechanism and the stapling can be to any object such as a bow and the stapling can include other means of attaching the ribbons together and/or attaching objects thereto such as by fusion or adhesives or pinning or card locking or the like. It is also to be understood that the shape and/or configuration of the drum can take any form so long as it rotates about an axis and is capable of supporting the ribbons around the periphery thereof. As one skilled in this art will appreciate, the length of the strands are determined by the circumference of the drum and obviously, the length of each strand will be predicated on the circumference selected for the drum. For example a drum whose circumference is 38 inches (approximately 12 inches in diameter) will produce a curled ribbon that is 38 inches long and hence each strand will be 19 inches long. [0056] The invention with respect to the hand operated embodiment can best be understood by referring to FIGS. 2 and 3. The portable hand operated curling machine generally illustrated by reference numeral 10 comprises the generally flat base 12 supporting a plurality of upstanding stub shafts or spindles 14 for supporting spools of ribbons 16 . In this instance, three spools of uncurled ribbons are shown, but it is to be understood that any number of spools can be utilized and the number of ribbons selected to form the curled ribbon end product is a matter of choice of the user. A complementary guide spool 18 for each of the spindles 14 are disposed between the curling mechanism 20 that is affixed to the base and the curling drum 26 for guiding the ribbon through the respective curling mechanism 20 . The curling mechanism will be described in detail hereinbelow. Each of the guide spools 18 are loosely fitted on a support spindle 22 affixed to base 12 . These guide spools 18 are free to rotate and afford substantially little if any resistance to the ribbon as is travels through the machine 10 . Another single guide spool 24 similarly attached to a support spindle affixed to base 12 and also loosely fitted to freely rotate is mounted between the curling mechanism 20 and the curling drum 26 and guides the three (3) ribbons in an overlapping configuration. [0057] The curling drum 26 is rotatably supported to a stub shaft 28 affixed to base 12 and rotates thereabout by virtue of the movement of the handle 30 . Essentially the curling drum 26 consists of at least three stations, namely, the attachment or clamping station 32 , the cutting station 34 , and the stapling station 36 . The attachment station 32 , the cutting station 34 and the stapling station 36 are slots or holes and slots that extend through the width of the drum 26 or at least a sufficient distance to perform the functions as will be described immediately below and are formed adjacent the periphery of the drum 26 . The distance between the cutting station 34 and the stapling station 36 determines at which point the ribbons will be attached to each other. As shown in this embodiment the curled ribbons are being attached at their respective ends. To attach the ribbons at another point, for example, the cutting slot is formed at cutting station 34 a . At this station the ribbon will be attached intermediate the ends and will form a decorative curled ribbon as shown in FIG. 1. [0058] In operation, each of the uncurled ribbons 16 are threaded and clamped through the respective curling mechanism, then laid adjacent to the respective guide spools 18 and then laid adjacent to the single guide spool 24 and the ends of the ribbons are held together in the overlapping position by the commercially available alligator clamp 38 which, in turn, is inserted by the operator into the aperture formed in the drum at the attachment station 32 . This secures the ribbons to the drum 26 . The operator with the use of the knob 40 affixed to handle 30 , rotates the drum 26 a number of revolutions until the desired end product is achieved, i.e. the number of curled ribbons constituting the end product is obtained. For example, if two (2) revolutions of the drum are made with three uncurled ribbons and the cut is 180° away from the staple station, the end product will include twelve (12) strands of curled ribbon emanating from the staple. On the other hand, if the cut is adjacent to the staple station, the number of strands of curled ribbons will be six (6), albeit twice as long. With an ordinary, commercially available stapler (not shown) with the base fitted into the slot 36 and the hammer head of the stapler straddling the ribbon, the staple is inserted into the ribbons. The stapling station 36 may include a wedged shaped portion 37 on either side of the slot which is designed to hold a card adjacent to the curled ribbons and in this instance the card is concomitantly stapled to the ribbons as shown in FIG. 1. The operator next, with the use of commercially available scissors (not shown) inserts the blades of the scissors to straddle the ribbons and snips the ribbons to produce the end item. Obviously, the ribbons can be cut with any other well known device, such as a knife or razor. The curled ribbons as processed by this portable curling machine produces the decorative piece as the end item which is ready for use to decorate a package, basket and the like. Obviously, from the foregoing it is easy to understand that the machine is so simple to operate that it is usable by practically all persons, is portable and sufficiently small and light weight to be easily stored. [0059] The next portion of this application will describe the automated curling machine generally indicated by reference numeral 50 . Like the drum described in connection with the hand operated curling machine depicted in FIG. 2, this automated machine 50 also includes a drum that wraps the ribbon around the periphery thereof and the drum includes stations for clamping the ribbon, stapling and cutting the ribbons as will be described hereinbelow. Before describing the entire machine, it is noted that the curling mechanism shown in FIGS. 5 and 6 is substantially the same as the curling mechanism utilized in connection with the machine depicted in FIG. 2 and for the sake of convenience and simplicity this curling mechanism is being described at this point in the disclosure. [0060] In its preferred embodiment the curling mechanism generally indicated by reference numeral 52 generally consists of two (2) generally cooperative flat plate elements 54 and 56 . Obviously, any type of mechanism that imparts a frictional force when the ribbon is moved in contact therewith that produces a curl can be employed. This particular mechanism has been selected because the exit angle can be changed so as to control the degree of curl in the ribbon as will be explained in more detail hereinbelow. The plate 54 may include a dowel pin 58 that fits into the drilled hole 60 to prevent the plate from rotating and a bolt 62 that fits through hole 64 formed in plate 56 and is threaded to the complementary threads 66 formed in the bore 68 to support the plates together leaving a small gap for allowing the ribbon to pass therebetween. The leading edge 70 of plate 54 is rounded to minimize the friction between that edge and the ribbon passing thereover and the portion 72 adjacent the bottom edge of the plate 56 is recessed and beveled to define a blade-like element where the ribbon comes into contact therewith as it is drawn thereover. A like configuration is provided on the diametrically opposed side to allow either side of the plate 56 to be used. [0061] As shown in FIG. 6 the ribbon as depicted by the arrow A is threaded over the curved surface of plate 54 and passes between plates 54 and 56 and then over the edge 74 of the recessed portion 72 and led away therefrom as indicated by arrow B. In these embodiments there is virtually no tension in the ribbon upstream of the curling mechanism 52 , save for the amount needed to allow the ribbon to progress through the machine and most of the tension on the ribbon occurs between the edge 76 and the drum. By virtue of this arrangement, the curling mechanism 52 can be oriented to change the angle C formed between the plate 56 and the ribbon. The angle C that is selected will determine the curvature of the curl in the ribbon. In other words, a more acute angle will impart a more severe curl and a less acute angle, i.e. an angle closer to 90 degrees will impart a larger diameter curl. [0062] In addition to the curling mechanism, as described above, the automated machine as best seen in FIG. 3 includes the rotating drum 80 with specific stations (similar to those depicted in FIG. 2), namely, the ribbon clamping station 82 , the cutting station 84 and the stapling station 86 . The ribbons are similar to FIG. 2 mounted on the base 86 and includes a slotted upstanding member 81 that guides each of the ribbons into the curling mechanism 52 , the guiding spools 83 and 85 also similar to that shown in FIG. 2. The base 88 supporting the drum 80 for rotary motion is supported in an upright position by a suitable cabinet 90 so that when the end product is completed it will fall by gravity to the bottom. The card feeding mechanism 92 which is sequentially placed in position at the stapling station may be pivotally mounted to swing radially outward away from drum 80 after the stapling so that after being cut in the cutting station 92 it will avoid being snag or tangled with the machinery. [0063] The actuators for controlling the function at the various stations of the drum during operation of the machine are supported internally of the drum in this embodiment and the actuators for controlling the card feeding and card cutting mechanisms are located away from the central portion of the drum and will be described in detail herelinbelow. A control panel generally illustrated by reference numeral 93 mounted on the machine includes suitable commercially available switches that serve to turn on and off the machine, to override the automatic sequence of the machine's functions which are controlled by a central processing unit 94 , that sequences the rotation of the drum, controls the various actuators both internal and external of the drum and the electric motor 96 , as will be explained hereinbelow. The main control for the machine is a special digital computer including a programmable logic controller unit (PLC) that serves to control the sequencing operations of the machine. The control panel may contain control buttons for jogging the rotational position of the drum, permitting individual actuation of the actuators so as to allow the initial threading of the ribbons, to initiate the automatic and continuous operation of the machine and may include an emergency stop. The PLC is commercially available, as for example, from the Mitsubishi Company of Japan and is of the type that can be programmed which is typically done by a computer programmer to perform the necessary functions as needed. [0064] [0064]FIGS. 4, 7 a , 7 b , 8 a , 8 b , 9 a , 9 b , 10 a and 10 b , illustrate schematically the details of the machine excluding the card feed and card cutting mechanisms. As noted therein the drum 80 at the clamping station 100 and cutting station 102 is flattened and this flattened portion 103 has disposed adjacent thereto the jaws 104 and 106 and the cutting blade 109 . Actuators 108 , 110 , 112 and 114 serve to control the position of jaws 104 and 106 . Actuator 108 serves to rotate jaw 104 , actuator 110 serves to rotate jaw 104 , actuator 112 serves to position jaw 104 radially outwardly relative to jaw 106 and actuator 114 serves to position both jaws 104 and 106 radially outwardly together with respect to the drum 80 . [0065] This portion of the description will describe the operation of the clamping mechanism and referring next to FIG. 7, the flattened portion 103 at clamping station 82 includes a recess portion 120 for receiving the jaws 104 and 106 and the partially annular groove 122 partially extending around the circumference receives and guides the first layer of the six (6) curled ribbons. As noted the jaws are in the clamped position in this FIG. 7. In the initial threading of the machine and before clamping this layer of curled ribbons between the jaws 104 and 106 , these jaws are positioned radially outwardly relative to drum 80 and jaw 104 is positioned radially outwardly with respect to jaw 106 providing a gap to accept the curled ribbons (noting that in this embodiment that each layer includes six (6) curled ribbons). Once the clamp is threaded, the jaws are brought together and retracted into the recess portion 120 to clamp the ribbons, and the initial layer of ribbons rides in groove 122 by virtue of actuating the electric servo motor 96 to rotate drum 80 . After the drum has rotated one or more revolutions depending on the number of strands that are required to make up the desired end product the clamping mechanism will be activated to release the layers of ribbons constituting the end product and re-activated to capture the layer of ribbons for the next cycle of operation so as to mass produce the end product. For example and for explanation purposes, assume that the end product will contain twenty-four (24) strands of curled ribbons emanating from the staple, noting that the cutting of the ribbon is 180° away from the stapling station, the drum will make two revolutions (each revolution of the layer of six (6) ribbons makes 12 strands relative to the staple). After the first revolution and when the second bundle of six curled ribbons overlay a portion of the first bundle of six curled ribbons, the combined underlayer and over layer will hold the ribbons to the drum without the assistance of the clamping mechanism. This portion of the machine's operation is shown in FIGS. 8 a and 8 b where it can be seen that the underlayer is clamped between the jaws and the over layer lies over the jaws. [0066] At this juncture point of the machine operation the jaws are actuated to perform a sequence of moves so as to clamp the next layer of six (6) ribbons to be ready for the next cycle. One cycle produces one end product. While the drum is rotating the cylinders 112 , 108 and 110 are actuated to open the jaws and rotate the jaws downwardly below the ribbon path. This permits the jaws to release the underlayer of ribbons and to be moved away from the path of the ribbons drawn over the drum 80 . Cylinder 114 is then actuated to position the jaws 104 and 106 away from the drum. This is demonstrated in FIGS. 9 a and 9 b. [0067] Before the completed revolution of the second layer of ribbons and during the first cycle, the lower jaw 104 is rotated back in the path of the ribbon by cylinder 110 as seen in FIGS. 10 a and 10 b . After the portion of the second layer of ribbons passes over the lower jaw 104 the cylinder 108 is actuated to bring the upper jaw 106 in line with the lower jaw 104 and the cylinder 112 is activated to bring both jaws together and clamp the ribbon as seen in FIGS. 11 a and 11 b . The jaws 104 and 106 are held radially outwardly away from drum 80 until after the cutting and stapling occurs and the next cycle commences. [0068] This portion of the description describes the cutting and stapling operation of the automatic curled ribbon making machine. After the clamp secures the bundle of ribbons to begin the next cycle, the motor is activated to the stop position. While it isn't necessary to stop the rotation of the drum since it is possible to perform the next operations while the drum is moving, in its preferred embodiment the stapling and cutting is done while the machine is at rest. To perform the cutting operation, cylinder 140 is actuated to rotate the blade 142 extending through an aperture 144 formed in drum 80 . Blade 142 is pivotally connected to drum 80 by the pin 146 and the reciprocating action of the connecting arm pivots the blade 142 to cause it to cut through the ribbon. [0069] Obviously, it is necessary to staple or join the respective layers of six ribbons prior to the cutting operation and this portion of the description describes the stapling operation of the machine. The stapling is accomplished in the preferred embodiment by a commercially available industrial type of cartridge feed stapler 146 which may be a Swingline stapler obtained from Swingline Inc. of Long Island City, N.Y. As best seen in FIGS. 12 a and 12 b the stapling is done at the stapling station 86 which similar to the cutting and clamping stations is a flattened portion 152 of the periphery of drum 80 . Stapler 146 includes a hammer 154 actuated by cylinder 156 that urges the continuous feed staple 158 toward the anvil 160 that causes one of the staples to pass through the ribbon and card 162 to secure all the individual ribbons and card together to form the end product. The raising and lowering of the anvil 160 is controlled by the cylinder 166 that pushes the pivoted links 188 and 200 via push rod 204 to cause the Y-shape to an I-shape to drive the anvil block 202 up and down. [0070] The automatic card feeder 220 as best shown in FIG. 13 serves to automatically feed the cards 222 between the anvil 160 and staple 154 (FIGS. 12 a and 12 b ). The cartridge of cards is feed to the feeder 220 and the cards are urged toward the anvil 160 via the actuator 224 until properly located. The commercially available rotary cutter 226 and cylinder 228 serve cut the card after being stapled to the ribbons. The automatic card feeder 220 is mounted to the base 88 (FIG. 3) adjacent to the drum 80 by the actuator 230 and push rod 232 which supports the automatic card feeder 220 for pivotal movement away from drum 80 once the card is attached to the ribbon and held by the automatic card feeder 220 . Once the end product is spaced away from the drum 80 the card is cut and released from the card feeder 220 and allowed to drop into a suitable carton or conveyor belt as the case may be. If necessary, a blow off nozzle or as many as need be may be employed to assure that the strands of ribbons, which are essentially free floating from the card, does not become ensnared with the mechanism. [0071] To understand the medium for controlling the various function of the automated curled ribbon curling machine and the interconnection between the various components reference will now be made to block diagram configuration of FIG. 14. In this diagram all of the solid lines represent electrical connection, all of the dash lines represent pressurized air feed hoses connections and all of the dot/dash lines represent feedback connections to the PLC. The PLC produces sequential signals to the individual commercially available solenoid valves generally indicated by reverence numeral 240 . Each cylinder is connected to the air manifold which is connected to a supply of pressurized air by virtue of opening and closing the respective solenoid valves to actuate and de-actuate the respective cylinder. Cylinder 108 actuating jaw 104 , cylinder 110 actuating jaw 106 , cylinder 140 actuating the cutter 142 and cylinder 166 actuating the anvil 160 are commercially available compressed air actuated actuators and suitable actuators of this type, for example are Clippard Cylinders available from the Clippard Instrument Laboratory, Inc. Of Cincinnati, Ohio. The cylinder 156 actuating the stapler and the cylinder 112 actuating the jaws to cause them to separate are also commercially available compressed air actuator and a suitable actuator is a Festo pneumatic actuator available from the Festo Inc. Of Hauppauge, N.Y. The cylinder 114 actuating both jaws together is also a compressed air actuator and a suitable actuator is a Fabco-Air available from Fabco-Air of Gainesville, Fla. The card feed actuator cylinder 224 and the rotary cutter cylinder 228 are also commercially available and a suitable actuator is a Bimba, available from Bimba Manufacturing Company, Monee, Ill. [0072] It is apparent from the foregoing that the PLC will generate sequential signals to cause the various solenoid valves 250 , 252 , 254 , 256 , 258 , 260 , 262 and 264 to interconnect or disconnect the compressed air from a suitable source 290 to feed each of the cylinders through the respective hoses 270 , 272 , 274 , 276 , 278 , 280 , 282 and 284 to perform the functions as was described in the above paragraphs. The blowoff nozzle 292 is shown and as noted above is utilized to assure that the end product doesn't become ensnared with the operating mechanism of the curled ribbon machine and is only used as needed. Feed back sensors for the cutter 142 , stapler 146 and anvil 160 serve to feed back the position of each cylinder to the PLC via the lines 294 , 296 and 298 . [0073] [0073]FIG. 15 is a block diagram similar to FIG. 14 but showing the functions that are not on the drum namely, the card feed cylinder 224 , the swing arm cylinder 230 , and the card cutter cylinder 226 . The solenoid valves 310 , 312 and 314 are controlled by the PLC and serve to connect the compressed air to the cylinders 224 , 230 and 226 via the air hoses 316 , 318 and 320 , respectively, for providing the respective functions. Feedback for the positions of these respective cylinders are fed back to the PLC through lines 322 . 324 and 326 , respectively. The PLC likewise controls the on/off and position of the motor via the motor driver 338 and encoder 340 . Each of the ribbons are provided with a break sensor 300 that is connected to the PLC via the feed back line 302 . [0074] What has been shown by this invention is different embodiments of a machine for making curled ribbon products, say a multicolored multiple ribbons formed into a plurality of strands of curled ribbon, either individually or by mass production. The individual making is by a portable hand operated machine that includes a drum or reel for winding the ribbon and drawing it through a curling mechanism, where the drum includes stations for attaching the ribbons to the drum, stapling the ribbons and a card or other item together, and cutting the ribbons to form the desired end product. In the mass production machine, the stations are formed on the periphery of the drum and the attaching is by a judiciously sequenced clamping mechanism and a automatic stapling mechanism that accepts cards from an automatic card feeding mechanism so as to staple the ribbons and card together and discretely positioned the end product away from the drum when releasing the end product from the machine. [0075] Although this invention has been shown and described with respect to detailed embodiments thereof it will be appreciated and understood by those skilled in the art that various changes in form and detail thereof may be made without departing from the spirit and scope of the claimed invention.
In one embodiment a hand operated machine for making curly ribbon products comprises a rotary drum that includes a station to attach the uncurled ribbons (more than one), a cutting station to cut the curled ribbons, and a stapling station to staple the ribbons together or to a card, ribbon, or the like. A handle is provided to rotate the drum and a fixed curling mechanism mounted downstream of the drum serves to curl the ribbon as the drum rotates to place the ribbon in contact with the curling mechanism. In another embodiment the machine is automated and includes a drum that has the same stations. The attaching station includes a pair of jaws that are sequentially movable one relative to the other and together to attain attaching the ribbons to the drum for the first cycle, detaching the ribbon during the first cycle and attaching the succeeding ribbon used in the next cycle for mass producing the curly ribbon product. The stapling and cutting are automatic and the card feeding machine is movable relative to the drum to avoid snarling the ribbon when released. The curling mechanism is adjustable to change the exit angle to select the desired curl characteristics of the curled ribbon.
3
BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] The present invention relates to a process of fabricating wafer-level underfilled microelectronic packages using over-bump application of a self-fluxing resin to a wafer, b-staging of the resin, dicing of the coated wafer, and joining the diced chips to substrates producing wafer-level underfilled microelectronic flip-chip packages. Moreover, the invention is further directed to the provision of microelectronic packages, which are produced in accordance with the inventive process. [0003] Flip Chip technology is the fastest growing chip interconnect technology today because it allows for very large numbers of I/Os. Thus the footprint of chips with low numbers of I/O's can be made very small. This also holds true for associated electronic packages, such as chip-scale packages. [0004] A major advantage of flip chip technology resides in that it can utilize the total chip area in order to provide the I/O connections, while contrastingly, wire bonding uses only the chip periphery. However, a disadvantage of flip chip technology consists of in that stresses which arise from a thermal mismatch between the silicon (chip) thermal expansion coefficient (CTE) and that of the substrate are fully borne by the solder bumps (C4s) that are used to effect the interconnections between chip and substrate. [0005] In order to ameliorate or possibly even eliminate such stresses, flip chip packages are usually underfilled, i.e., a resin is placed between the chip and the substrate and resultingly acts as an encapsulant of the solder bumps and an adhesive between chip and substrate. The effect of such underfills resides in that the long-term reliability of underfilled flip chip packages is greatly enhanced compared to their counterparts which are not underfilled. [0006] Underfills can be applied by either capillary flow, by using a so-called no-flow process, or by wafer-level applied processes. There are several wafer-level applied underfill processes, among them the Wafer-level Underfill (WLUF) Process which uses an over-bump applied resin, that is then b-staged, the wafer is then diced to singulate chips, and finally the chips are joined to substrates. [0007] 2. Discussion of the Prior Art [0008] The foregoing process is generally described in Buchwalter, et al., U.S. Pat. No. 6,919,420 B2, which is commonly assigned to the present assignee, and the disclosure of which is incorporated herein in its entirety, wherein there is employed a reworkable thermoset acid-cleavable acetal and ketal based epoxy oligomers, which can be B-staged into a tack free state. The process described in that patent also covers non-reworkable thermosets. [0009] Buchwalter, et al., U.S. Pat. No. 6,924,171 B2, which is commonly assigned to the present assignee, and the disclosure of which is incorporated herein in its entirety, disclose a similar aspect as the preceding patent which provides for a method of fabricating microelectronic interconnection structures, as well as the structures formed by the methods for improving manufacturing throughput for assembling flip chip semiconductor devices, and wherein oligomers may be employed, as in the preceding U.S. patent to Buchwalter, et al., U.S. Pat. No. 6,919,420 B2. [0010] The publication “A Wafer-level Underfill Process for Flip-chip Packaging”, C. Feger, et al., Proc. IMAPS Flip Chip Tech; 2003, also discloses a wafer-level underfill process for flip chip packaging. SUMMARY OF THE INVENTION [0011] In order to improve upon the state-of-the-technology in the provision of WLUF processes, according to the present invention, the foregoing process has been refined so as to render it more useful and efficient in connection with various applications thereof in the electronics industry. [0012] Pursuant to the invention, a novel WLUF process resides in employing wafers that have solder bumps of essentially equal height, such as are obtained using the C4NP process (Controlled Collapse Chip Connection—new process), as is known in the prior art. This process allows for the provision of wafers in which the bump height is very uniform, considerably more so than in plated bumps. The presence of uniform bump height is advantageous in the WLUF process since it ensures that all bumps are coated to a uniform height. This facilitates that the thickness of the WLUF material through which the bumps require to be pushed through in order to make contact with the pads of the substrate, can be selected so as to be uniform. It further ensures that substantially all bumps will make contact with the corresponding substrate pads after the bumps have pushed through the coating. Moreover, the coating of the bumps with the WLUF material protects the bumps from excessive oxidation thereof. [0013] Another advantage obtained by the present invention is to improve the WLUF process by employing wafers which were first tested prior to the wafer-level underfill (WLUF) material being applied to the bumped wafer in a manner that covers the majority of the bumps. This is accomplished by using methods known in the field to identify known-good dies. [0014] The present invention further enables the achievement of an excellent degree of underfill adhesion by cleaning of the wafer before WLUF application. For example, a chip is normally cleaned after joining it to the substrate through using a flux to allow for C4 reflow. This cleaning step is difficult, particularly for small C4 bump sizes and large chips, since it is difficult to get the cleaning solutions into and out of small gaps. However, cleaning is absolutely necessary to be able to ensure good underfill adhesion, since without the presence of good adhesion, the reliability of the package containing the underfill is severely limited. Cleaning steps that are taken may involve cleaning with diluted acids, such as sulphuric acid, washing with an aqueous detergent solution followed by a DI rinse and rinsing with IPA, and/or oxygen plasma etching. In the WLUF process pursuant to the current invention, a bumped wafer is prepared for WLUF deposition by cleaning the wafer after bumping through processes that are typical for after bump and/or after solder join operations; whereby the wafers are then baked in order to remove volatiles from the surface and/or the passivation layer (particularly if there is used a polymeric passivation layer, such as photosensitive polyimide) just before application of the WLUF material, so that the bumps are largely coated by a layer of WLUF material. [0015] Moreover, the present invention produces wafers that are protected by the WLUF material during wafer thinning and during subsequent handling. Since wafers are often thinned down to between 300 and 30 microns they tend to become quite fragile. Adding an organic, b-staged resin with a modulus of about 0.5-1 GPa and a thickness that exceeds the height of the bumps by 1-100 μm, imparts a significant degree of robustness to the wafer, and thereby decreases possible damage due to handling. The B-staged WLUF coating also protects the extremely fragile chip interconnect structure; an aspect that may be particularly advantageous in the development of future, low-k interlayer dielectric interconnects, whereas the WLUF also protects the solder bumps from excessive oxidation during storage. [0016] Finally, chips, which are protected by a WLUF material, enjoy the benefit of the underfill already during the first cool down after chip join. Fragile low-k dielectric interconnect structures are easily broken during this first cool down through the stresses imparted by the CTE mismatch of the chip and substrate, however, since the WLUF material substantially or fully cures during chip join it provides the function of the underfilling extending reliability and life expectancy ab initio. [0017] Accordingly, it is an object of the present invention to provide an improved wafer-level underfill process in the fabrication of microelectronic packages. [0018] A more specific object of the invention resides in the provision of an improved wafer-level underfill process utilizing an over-bump application of a self-fluxing resin to a wafer, particularly as employed in the flip-chip technology. [0019] Still another object of the present invention is to provide a microelectronic package employing the improved wafer-level underfill process as disclosed herein. BRIEF DESCRIPTION OF THE DRAWINGS [0020] Reference may now be made to the following detailed description of the invention, taken in conjunction with the accompanying drawings; in which: [0021] FIG. 1 a discloses a schematic representation of a plated non-uniformily sized bump structure on a chip with B-stage wafer-level applied over bump underfill (WLUF); [0022] FIG. 1 b illustrates a non-wet bump connection caused by non-uniform bump size and the inclusion of pockets of air obtained after chip to substrate joining of such a chip; [0023] FIG. 2 a illustrates a schematic of a chip with non-uniformly bumped solder balls, which are coated by wafer-level-applied, B-staged, over-bump underfill (WLUF); [0024] FIG. 2 b illustrates the package after vacuum assisted chip to substrate joining, which does not exhibit any air inclusions but still exhibits the non-wet; [0025] FIGS. 3 a and 3 b illustrate, respectively, uniformly sized solder bumps WLUF process steps pursuant to the present invention; [0026] FIG. 4 illustrates, in an exploded view, a Step 1 of wafer bumping using C4NP and in a Step 2 wafer cleaning followed by uniform coating of bumped wafer with WLUF; [0027] FIG. 5 illustrates, in an exploded view, wafer dicing, and then chip joining while minimizing any voids; [0028] FIGS. 6 a and 6 b illustrate, in an exploded view, the sequence of steps in producing the joining thereof in more detail; [0029] FIG. 7 a illustrates, diagrammatically, in an exploded view, cleaning to remove flux residue and providing capillary underfill; [0030] FIG. 7 b illustrates steps in the preparation of the surface and application of underfill to the wafer; [0031] FIG. 8 a illustrates unprotected C4 solder balls; [0032] FIG. 8 b illustrates C4 solder balls protected by WLUF; [0033] FIG. 9 a illustrates the joining and cooling steps with the C4 bumps not being protected by WLUF; and [0034] FIG. 9 b illustrates the joining and cooling steps with the C4 bumps being protected by the WLUF pursuant to the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0035] Throughout the several drawing views, elements and structures which are similar or identical to each other, will be designated with the same reference numerals. [0036] Referring in specific detail to the drawings, the inventive over-bump wafer-level underfill process requires that the WLUF (wafer-level underfill) material 10 is applied to a fully bumped wafer 12 so that a layer 14 of the WLUF material covers the solder bumps 16 , 18 . If the WLUF layer 14 is uniform and flat, irrespective if the solder bumps 16 , 18 are different in size, and does not show large peaks and valleys, little or no air is entrapped during the subsequent joining of singulated WLUF coated chips to substrates. Air entrapment is undesirable since it reduces the reliability of the finished semiconductor package 20 . [0037] Plated bumps 16 , 18 tend to exhibit significant bump height variations, as shown in FIG. 1 a . When a WLUF material coats wafers 12 with such plated bumps 16 , 18 and chips 22 obtained from such a coated wafer 12 are joined to a substrate 24 , air inclusions 26 at the substrate—underfill interface 28 are likely to occur, as shown in FIG. 1 b . Further smaller bumps 16 will not wet the substrate pad which may cause an open circuit and a fail of the package. [0038] It is possible to avoid these air inclusions 26 or pockets by using a vacuum during joining 30 , as shown in FIGS. 2 a and 2 b during a chip joining process. However, so-called pick-and-place tools, which can provide a local vacuum, are currently not available commercially but are under development. It is possible to avoid these air inclusions also by applying a drop of a thermosetting material that may be the substantially unfilled WLUF material 10 at the center 32 of either the C4 pad array of the substrate 24 (preferred), or of the chip 22 with a b-staged WLUF material layer 14 , whereby the drop has to be substantially solvent free before the joining process in order to avoid any inclusion of solvent. This can be achieved by either providing a solvent-free version of the underfill 10 that is applied by heating the material above the Tg, and extruding the material onto the chip 22 or substrate 24 , by applying the same solution used for spin-application and then using b-stage conditions to dry the drop, or by using a substantially unfilled version of the WLUF material or of a similar material. The drop aids in excluding air 26 since upon joining it will be pushed out to the chip edge 22 , while driving air in front thereof to the outside. [0039] It is advantageous for the WLUF process to be conducted with the wafer 12 having uniform size balls 18 , as shown in FIGS. 3 a and 3 b , such as are created with a C4NP process, as mentioned since the size uniformity ensures that all solder connections to the substrate pad will be made. Experiments have shown that C4NP bumped wafers coated with a WLUF material 10 achieved 100% electrical connectivity after joining of WLUF coated chips to substrates. Using the described process precautions and wafers with uniform bumps and applied WLUF material and chips which are obtained from such wafers by dicing, as in FIG. 4 , offer the best path to obtaining reliable, WLU-filled semiconductor packages 20 . [0040] Once a WLUF material 10 coats a wafer 12 , the solder bumps 16 , 18 are covered by a layer of a dielectric insulator. This means that electrical connections can only be made during the joining process. An advantage of that situation resides in that the solder bumps 16 , 18 are protected by the WLUF material 10 from severe oxidation and from handling damage which may be particularly severe with a fragile low-k interlayer dielectric. A drawback of the fact that the bumps are coated is that alignment of both wafers during dicing and chips during chip to substrate joining may be somewhat more difficult. [0041] In a wafer 12 coated by a WLUF layer 10 , the solder bumps 16 , 18 are covered by a dielectric insulator, whereby this precludes testing the functionality of chips prior to dicing. This problem can be avoided by testing the wafers 12 prior to application of the wafer-level underfill (WLUF) material 10 . [0042] A major factor influencing the reliability of flip chip packages 20 is the adhesion of the underfill 10 to all surfaces and particularly to a chip passivation layer 34 , as shown in FIG. 4 . Excellent adhesion is achieved usually by cleaning the package 20 after chip joining prior to underfilling the chip. This cleaning step, which removes flux residue and any other contaminants, is absolutely necessary to ensure good underfill adhesion. Cleaning steps may involve cleaning with diluted acids such as sulphuric acid, washing with an aqueous detergent solution followed by DI rinse and rinsing with IPA, and/or oxygen plasma etching. Cleaning becomes increasingly more difficult as the chip size increases, the C4 bump pitch decreases, the bump density increases and the gap between chip and substrate decreases. This problem is solved using the WLUF process by cleaning the wafer 12 before WLUF application and the substrate 24 before joining. Hereby, as illustrated in FIGS. 7 a and 7 b , there is represented the cleaning process in removing flux residue and providing capillary underfill. The joining is shown in drawing FIGS. 6 a and 6 b. [0043] In order to prepare the bumped wafer 12 in the WLUF process the passivation layer 34 is baked out using standard processes known to those in the field. A cleaning step using one of the above methods may be incorporated before the baking step. If the WLUF process is incorporated in the Far Back End of Line (FBEOL) process flow the last step of which often is a surface cleaning step, no further cleaning is necessary and the WLUF material 10 can be spun on and b-staged as one of the last steps of the FBEOL process. This is desirable since the WLUF layer protects the wafer 12 during wafer thinning and during subsequent handling. [0044] Since wafers are often thinned down to 300 to 30 μm they become quite fragile. Adding an organic, b-staged resin 38 with a modulus of 0.1-1 GPa and a thickness that exceeds the height of the solder bumps 18 by 1-100 μm provides significant robustness to the wafer 12 and decreases handling damage. It is advantageous to apply the WLUF coating and b-staging same before wafer thinning. The wafer can then be placed with the b-staged WLUF side onto a polishing pad such as known to those skilled in the art. Thinning can then proceed. A further advantage of this method is that wafers can be bumped before thinning avoiding handling of thin fragile wafers during the bumping process. The b-staged WLUF coating 10 also protects the very fragile chip interconnect structure; something that is particularly advantageous in low-k interlayer dielectric interconnects. Also the WLUF protects the solder bumps 18 from excessive oxidation during storage. This may be as represented in FIGS. 4 , 8 a and 8 b of the drawings. [0045] Chips, which are protected by a WLUF material, derive the benefit of the underfill already during the first cool down after chip join. Experiments have shown that the WLUF process can indeed protect the fragile low-k dielectric interconnect structure which without this process are easily broken during this first cool down through the stresses imparted by the CTE mismatch of the chip and substrate. This distinction is clearly represented in, respectively, FIGS. 9 a and 9 b of the drawings. Since the WLUF material cures substantially or fully during chip join it provides the function of underfilling in extending reliability and lifetime from the get go. [0046] While the present invention has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in forms and details may be made without departing from the spirit and scope of the present invention. It is therefore intended that the present invention not be limited to the exact forms and details described and illustrated, but to fall within the spirit and scope of the appended claims.
A process of fabricating wafer-level underfilled microelectronic packages using over-bump application of a self-fluxing resin to a wafer, b-staging of the resin, dicing of the coated wafer, and joining the diced chips to substrates producing wafer-level underfilled microelectronic flip-chip packages. Moreover, provided are microelectronic packages, which are produced in accordance with the inventive process.
7
TRADEMARKS [0001] IBM® is a registered trademark of International Business Machines Corporation, Armonk, N.Y., U.S.A. S/390, Z900 and z990 and other names used herein may be registered trademarks, trademarks or product names of International Business Machines Corporation or other companies. BACKGROUND OF THE INVENTION [0002] This invention relates generally to data conversion, and more particularly, to converting a number from binary to decimal using a five bit code. [0003] Decimal calculations are becoming more prevalent in today's computers. For example, all financial calculations are inherently decimal calculations. However, most computers operate more efficiently on binary data because the digital circuits are optimized for two-value logic. This causes a need to convert decimal formats to binary formats and vice versa. Currently, look-up tables and decimal adders to accumulate the results are utilized to perform conversions from binary formats to decimal formats. In designs where the frequency is very high, a decimal adder requires multiple cycles. Also there are space concerns associated with using look-up tables. In addition, the use of a look-up table can have negative impact on the speed of the conversion. It would be desirable to be able to perform the conversion from binary to decimal as efficiently as possible in order to provide a high performance computer system. BRIEF SUMMARY OF THE INVENTION [0004] Exemplary embodiments of the present invention include a method for converting from binary to decimal. The method includes receiving a binary number, the binary number including one or more sets of bits. An accumulated sum is set to zero. The accumulated sum is in a binary coded decimal (BCD) format. The following loop is repeated for each set of bits in the binary number in order from the set of bits containing the most significant bit of the binary number to the set of bits containing the least significant bit of the binary number: the accumulated sum is converted into a 5,1 code format resulting in an interim sum. The loop also includes repeating for each next bit in the set in order from the most significant bit to the least significant bit in the set: doubling the interim sum; and replacing the least significant bit of the interim sum with the next bit. The last step in the loop includes converting the interim sum into the BCD format and storing the results of the converting in the accumulated sum. Once all of the sets of bits in the binary number have been processed through the loop, the accumulated sum is output as the final result. [0005] Additional exemplary embodiments include a method for converting from binary to decimal. The method includes receiving a binary number, the binary number including one or more sets of bits. An accumulated sum is set to zero, where the accumulated sum is in a binary coded decimal (BCD) format. The accumulated sum is converted into a 5,1 code format resulting in an interim sum. The following loop is repeated for each set of bits in the binary number in order from the set of bits containing the most significant bit of the binary number to the set of bits containing the least significant bit of the binary number: repeating for each next bit in the set in order from the most significant bit to the least significant bit in the set: doubling the interim sum; and replacing the least significant bit of the interim sum with the next bit. At the end of the loop the interim sum is converted into the BCD format and storing the result in the accumulated sum the accumulated sum is output as the final result. [0006] Additional exemplary embodiments include a system for converting from binary to decimal. The system includes an input latch for storing a binary number that includes one or more sets of bits. The system also includes an accumulated sum latch for storing a BCD formatted accumulated sum and an interim sum latch for storing a 5,1 code formatted interim sum. The system further includes a mechanism for receiving the binary number into the input latch and setting the accumulated sum to zero. The following loop is repeated for each set of bits in the binary number in order from the set of bits containing the most significant bit of the binary number to the set of bits containing the least significant bit of the binary number: the accumulated sum is converted into a 5,1 code format resulting in an interim sum. The loop also includes repeating for each next bit in the set in order from the most significant bit to the least significant bit in the set: doubling the interim sum; and replacing the least significant bit of the interim sum with the next bit. The last step in the loop includes converting the interim sum into the BCD format and storing the results of the converting in the accumulated sum. Once all of the sets of bits in the binary number have been processed through the loop, the accumulated sum is output as the final result. [0007] Further exemplary embodiments include a system for converting from binary to decimal. The system includes an input latch for storing a binary number that includes one or more sets of bits. The system also includes an accumulated sum latch for storing a BCD formatted accumulated sum and an interim sum latch for storing a 5,1 code formatted interim sum. The system further includes a mechanism for receiving the binary number into the input latch and setting the accumulated sum to zero. The accumulated sum is converted into a 5,1 code format resulting in the interim sum. The following loop is repeated for each set of bits in the binary number in order from the set of bits containing the most significant bit of the binary number to the set of bits containing the least significant bit of the binary number: repeating for each next bit in the set in order from the most significant bit to the least significant bit in the set: doubling the interim sum; and replacing the least significant bit of the interim sum with the next bit. At the end of the loop the interim sum is converted into the BCD format and storing the result in the accumulated sum the accumulated sum is output as the final result. [0008] Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and to the drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0009] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which: [0010] FIG. 1 is a block diagram of a binary to decimal converter that may be utilized by exemplary embodiments of the present invention; [0011] FIG. 2 is a block diagram of a binary to decimal converter that may be utilized by exemplary embodiments of the present invention; [0012] FIG. 3 is a table that depicts BCD digits and corresponding 5,1 code digits as utilized by exemplary embodiments of the present invention; [0013] FIG. 4 depicts circuitry for an exemplary BCD to 5,1 code recoder that may be utilized by exemplary embodiments of the present invention; [0014] FIG. 5 depicts circuitry for an exemplary 5,1 code to BCD recoder that may be utilized by exemplary embodiments of the present invention; and [0015] FIG. 6 depicts circuitry for an exemplary 5,1 code doubler that may be utilized by exemplary embodiments of the present invention. [0016] The detailed description explains the preferred embodiments of the invention, together with advantages and features, by way of example with reference to the drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0017] Exemplary embodiments of the present invention include an algorithm for converting binary data to binary coded decimal (BCD) data. The algorithm is very efficient and may be implemented in machines with very fast cycle times. The conversion algorithm converts one binary bit to decimal and accumulates it. The speed of exemplary embodiments of the circuitry associated with the algorithm allows multiple circuits to be concatenated together to reduce multiple bits per cycle. In exemplary embodiments of the present invention, four stages per cycle are assembled to reduce four binary bits per cycle. This could easily be modified to do more or less bits per cycle because the building block is very small. [0018] FIG. 1 is a block diagram of a binary to decimal converter that may be utilized by exemplary embodiments of the present invention. It includes a binary operand latch 102 for storing a binary operand that will be converted to a BCD format. The binary operand latch 102 shifts left once for each cycle through the processing depicted in FIG. 1 . In this manner it feeds the MSB of the binary operand into the 5,1 code doubler 110 during the first cycle, the second MSB during the second cycle, the third MSB during the third cycle and so on until all bits in the binary operand latch 102 have been input to the 5,1 code doubler 110 . [0019] Also included in the binary to decimal converter depicted in FIG. 1 is a decimal accumulated sum latch 104 for storing a running sum associated with the resultant BCD number. At the start of the conversion process, the decimal accumulated sum latch 104 is reset to zero. Output from the decimal accumulated sum latch 104 includes digits in a BCD format. At the end of the conversion, the decimal accumulated sum latch 104 contains the final BCD result 114 . [0020] The BCD formatted data from the decimal accumulated sum latch 104 is input to a BCD to 5,1 code recoder 108 for converting the BCD formatted data into 5,1 code formatted data. Exemplary circuitry that may be utilized to implement the BCD to 5,1 code recoder 108 is depicted in FIG. 4 and described below. The output from the BCD to 5,1 code recoder 108 and the next most significant binary bit 106 of the binary operand is input to a 5,1 code doubler 110 . The 5,1 code doubler 110 performs the conversion from binary to 5,1 code format. Exemplary circuitry that may be utilized to implement the 5,1 code doubler 110 is depicted in FIG. 6 and described below. Output from the 5,1 code doubler 110 is in a 5,1 code format and is input to a 5,1 code to BCD recoder 112 . The 5,1 code to BCD recoder 112 converts the 5,1 code data into BCD data. The BCD data that is output is then input to the decimal accumulated sum latch 104 for use during the next cycle through the processing depicted in FIG. 1 . [0021] FIG. 2 is a block diagram of a binary to decimal converter that may be utilized by exemplary embodiments of the present invention. It is similar to the binary to decimal converter depicted in FIG. 1 except that more than one bit of data is being converted in each cycle. The binary operand latch 102 is shifted left “n bits” and the “n bits” are fed to “n” 5,1 code doublers 110 , as depicted in FIG. 2 . In this manner n bits are being converted during each cycle. This results in a higher performance binary to decimal converter than the one depicted in FIG. 1 because more bits are being converted per cycle. [0022] FIG. 3 is a table that depicts BCD digits and corresponding 5,1 code digits as utilized by exemplary embodiments of the present invention. The conversion is based on the following logic. First, when doubling a BCD digit, the carryout propagates to the LSB of the next most significant digit (MSD), and the LSB of the digits is always zero. [0000] As shown below: [0023] 0000→0000 [0024] 0001→0010 [0025] 0010→0100 [0026] 0011→0110 [0027] 0100→1000 [0028] 0101→1,0000 [0029] 0110→1,0010 [0030] 0111→1,0100 [0031] 1000→1,0110 [0032] 1001→1,1000 [0033] In the above list, the number preceding the comma is the carry out (e.g., for entry “1, 0000”, “1” is the carry out). The LSB of the result is always zero and the carry out may be held for the next less significant doubled digit. When the BCD is recoded to five bits with weights of 8, 6, 4, 2, 0, respectively, and one additional bit indicates whether the value is odd or even, the result is the values depicted in FIG. 3 . [0034] The following is an example of a conversion from binary to BCD utilizing exemplary embodiments of the present invention as described herein. In this example, 4 bits are being converted per cycle (i.e., four 5,1 code doublers 110 are utilized) and, for simplicity of the example, the resulting BCD number has a maximum of two digits. The number to be converted is binary “00100100” which will become “00110110” in BCD via the processes and circuitry described herein. b 0 b 1 b 2 b 3 b 4 b 5 b 6 b 7 0 0 1 0 0 1 0 0 FIRST LOOP: BCD to 5,1 Code Recoder: 1 st digit = 0000 BCD 2 nd digit = 0000 BCD 1 st digit = 000010 5,1 Code 2 nd digit = 000010 5,1 Code 1 st 5,1 Code Doubler: 1 st digit = 000010 5,1 Code 2 nd digit = 000010 5,1 Code Double 2 nd digit and replace LSB with b 0 2 nd digit = 000010 5,1 Code Carry out from 2 nd digit is 0 Double 1 st digit and replace LSB with carry out from 2 nd digit 1 st digit = 000010 5,1 Code 2 nd 5,1 Code Doubler: 1 st digit = 000010 5,1 Code 2 nd digit = 000010 5,1 Code Double 2 nd digit and replace LSB with b 1 2 nd digit = 000010 5,1 Code Carry out from 2 nd digit is 0 Double 1 st digit and replace LSB with carry out from 2 nd digit 1 st digit = 000010 5,1 Code 3 rd 5,1 Code Doubler: 1 st digit = 000010 5,1 Code 2 nd digit = 000010 5,1 Code Double 2 nd digit and replace LSB with b 2 2 nd digit = 000011 5,1 Code Carry out from 2 nd digit is 0 Double 1 st digit and replace LSB with carry out from 2 nd digit 1 st digit = 000010 5,1 Code 4 th 5,1 Code Doubler: 1 st digit = 000010 5,1 Code 2 nd digit = 000011 5,1 Code Double 2 nd digit and replace LSB with b 3 2 nd digit = 000100 5,1 Code Carry out from 2 nd digit is 0 Double 1 st digit and replace LSB with carry out from 2 nd digit 1 st digit = 000010 5,1 Code 5,1 Code to BCD Recoder: 1 st digit = 000010 5,1 Code 2 nd digit = 000100 5, 1 Code 1 st digit = 0000 BCD 2 nd digit = 0010 BCD SECOND LOOP BCD to 5,1 Code recoder: 1 st digit = 0000 BCD 2 nd digit = 0010 BCD 1 st digit = 000010 5,1 Code 2 nd digit = 000100 5,1 Code 1 st 5,1 Code Doubler: 1 st digit = 000010 5,1 Code 2 nd digit = 000100 5,1 Code Double 2 nd digit and replace LSB with b 4 2 nd digit = 001000 5,1 Code Carry out from 2 nd digit is 0 Double 1 st digit and replace LSB with carry out from 2 nd digit 1 st digit = 000010 5,1 Code 2 nd 5,1 Code Doubler: 1 st digit = 000010 5,1 Code 2 nd digit = 001000 5,1 Code Double 2 nd digit and replace LSB with b 5 2 nd digit = 100001 5,1 Code Carry out from 2 nd digit is 0 Double 1 st digit and replace LSB with carry out from 2 nd digit 1 st digit = 000010 5,1 Code 3 rd 5,1 Code Doubler: 1 st digit = 000010 5,1 Code 2 nd digit = 100001 5,1 Code Double 2 nd digit and replace LSB with b 6 2 nd digit = 100000 5,1 Code Carry out from 2 nd digit is 1 Double 1 st digit and replace LSB with carry out from 2 nd digit 1 st digit = 000011 5,1 Code 4 th 5,1 Code Doubler: 1 st digit = 000011 5,1 Code 2 nd digit = 100000 5,1 Code Double 2 nd digit and replace LSB with b 7 2 nd digit = 010000 5,1 Code Carry out from 2 nd digit is 1 Double 1 st digit and replace LSB with carry out from 2 nd digit 1 st digit = 000101 5,1 Code 5,1 Code to BCD Recoder: 1 st digit = 000101 5,1 Code 2 nd digit = 010000 5, 1 Code 1 st digit = 0011 BCD 2 nd digit = 0110 BCD BCD Result = 00110110 [0035] FIG. 4 depicts circuitry for an exemplary BCD to 5,1 code recoder that may be utilized by exemplary embodiments of the present invention. The four bits making up one BCD digit (i.e., X 0 , X 1 , X 2 , and X 3 ) are input and the output result is the six bits making up the corresponding 5,1 code digit (i.e., Y 8 , Y 6 , Y 4 , Y 2 , Y 0 , and Y odd ). [0036] FIG. 5 depicts circuitry for an exemplary 5,1 code to BCD recoder that may be utilized by exemplary embodiments of the present invention. The five bits making up a 5,1 code digit (i.e., Y 8 , Y 6 , Y 4 , Y 2 , Y 0 , and Y odd ) are input and the output result is the four bits making up the corresponding BCD digit (i.e., X 0 , X 1 , X 2 , and X 3 ). [0037] FIG. 6 depicts circuitry for an exemplary 5,1 code doubler that may be utilized by exemplary embodiments of the present invention. A digit expressed in 5,1 code is input (i.e., Y) and the output is the digit doubled (i.e., Z) and expressed in 5,1 code. The circuitry depicted in FIG. 6 may be expressed by the formulas that follow. Z 8 =Y odd *Y 8 +{overscore (Y)} odd Y 4 Z 6 =Y odd *Y 2 +{overscore (Y)} odd *Y 8 Z 4 =Y odd *Y 6 +{overscore (Y)} odd *Y 2 Z 2 =Y odd *Y 0 +{overscore (Y)} odd *Y 6 Z 0 =Y odd *Y 4 +{overscore (Y)} odd *Y 0 Z odd =Y 8 +Y 6 +Y odd *Y 4 for all but the least significant group Z odd =b i for the least significant bit Note that Z odd is actually the carry out of this digit and it is transmitted to the next more significant digit, whereas Z8, Z6, Z4, Z2, and Z0 remain with the positional weighting of the current digit. [0038] Exemplary embodiments of the present invention provide an efficient binary to decimal converter. Converting to 5,1 code allows the doubling to be performed without the performance impacts associated with propagated carry chains. The 5,1 code also allows most of the equations (Z8, Z6, Z4, Z2, and Z0) to be expressed in terms of 2 to 1 multiplexer where the select signals are the true and complement of Y odd . This type of multiplexer is extremely fast if implemented in circuits as a pass gate multiplexer, and has a speed advantage over prior art BCD doublers. In exemplary embodiments of the present invention four bits are converted during each clock cycle providing for a relatively quick conversion between a binary number and a BCD number. [0039] The capabilities of the present invention can be implemented in software, firmware, hardware or some combination thereof. [0040] As one example, one or more aspects of the present invention can be included in an article of manufacture (e.g., one or more computer program products) having, for instance, computer usable media. The media has embodied therein, for instance, computer readable program code means for providing and facilitating the capabilities of the present invention. The article of manufacture can be included as a part of a computer system or sold separately. [0041] Additionally, at least one program storage device readable by a machine, tangibly embodying at least one program of instructions executable by the machine to perform the capabilities of the present invention can be provided. [0042] The flow diagrams depicted herein are just examples. There may be many variations to these diagrams or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention. [0043] While the invention has been described with reference to exemplary 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. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another.
A method for converting from binary to decimal. The method includes receiving a binary number, the binary number including one or more sets of bits. An accumulated sum is set to zero. The accumulated sum is in a binary coded decimal (BCD) format. The following loop is repeated for each set of bits in the binary number in order from the set of bits containing the most significant bit of the binary number to the set of bits containing the least significant bit of the binary number: the accumulated sum is converted into a 5,1 code format resulting in an interim sum. The loop also includes repeating for each next bit in the set in order from the most significant bit to the least significant bit in the set: doubling the interim sum; and replacing the least significant bit of the interim sum with the next bit. The last step in the loop includes converting the interim sum into the BCD format and storing the results of the converting in the accumulated sum. Once all of the sets of bits in the binary number have been processed through the loop, the accumulated sum is output as the final result.
7
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a catalyst for purifying exhaust gases that contain nitrogen oxides (NOx), carbon monoxide (CO), and hydrocarbons. 2. Description of the Related Art For the purification treatment of exhaust gases from automobiles and other similar sources, catalysts (composition: Pt, Rh/Al 2 O 3 system) known as three-way catalysts which utilize hydrocarbons and CO in the automotive emissions are usually used. The three-way catalysts are normally prepared by applying a γ-alumina slurry to a refractory carrier of cordierite or the like, baking, and then causing the carrier to support a metal, e.g., Pt, Rh, or Pd. They cannot remove NOx, hydrocarbons, and CO, however, unless the combustion occurs within a very narrow range close to the theoretical air-fuel ratio (e.g., A/F=14.6). With growing concern over the global environments in recent years, there has been strong demand for fuel-efficient cars. Accordingly, lean-burn engines for combustion above the theoretical air-fuel ratio have arrested attention as a key technology. It is well-known that the fuel efficiency is improved by burning in the engine a fuel mixture of an increased air-fuel ratio (A/F). However, this is accompanied by an increase in the oxygen concentration in the exhaust to such a level that while an ordinary three-way catalyst can remove hydrocarbons and CO, it does not remove NOx. To purify the exhaust gas in the "lean-burn" region where the oxygen concentration is high, it has already been proposed to use catalysts consisting of a transition metal, such as Cu, supported by a zeolite of the general formula, xM 2 / n O.Al 2 O 3 .ySiO 2 , wherein M is an n-valent metal (see, e.g., Japanese Patent Provisional Publications Nos. 125250/1985 (60-125250) and 130735/1989 (1-130735)). Another catalyst has also been introduced to meet the end which comprises a crystalline silicate to which Cu is added, the silicate itself having a chemical composition, (1±0.4)R 2 O.[aM 2 O 3 .bAl 2 O 3 ].ySiO 2 , in which R is an alkali metal ion and/or hydrogen ion, M is the ion of at least one element selected from the group consisting of Group VIII elements, rare earth elements, titanium, vanadium, chromium, niobium, and antimony, a+b=1.0, a≦0, b>0, and y>12 (Japanese Patent Provisional Publication No. 303194/1989 (1-303194)). While these recently introduced catalysts exhibit satisfactory initial activities, they have the disadvantage of limited durability. Exhaust gases from ordinary lean-burn engines are at high temperatures over a broad range of 300° to 700° C., and conventional catalysts used for such engines have been found to deteriorate due to sintering of the supported active metal. Also, the present inventors have found that the catalytic deterioration of such conventional catalysts is accelerated by demetallization, a phenomenon in which aluminum and iron in the crystal lattices, which form ion exchange sites in the catalyst carrier zeolite and crystalline silicate, are removed from the crystal lattices under the influence of the high temperature exhaust gas atmosphere, especially in the presence of steam. SUMMARY OF THE INVENTION In view of the state of the art summarized above, an object of this invention is to provide a catalyst for purifying exhaust gases which is highly resistant to heat and steam and which does not have the drawbacks of conventional catalysts. In order to develop a catalyst with great resistance to heat and steam, it is necessary to avoid the separation of aluminum or iron from the carrier, and it has been found that if aluminum remains stably in the crystal lattice, the degree of sintering of the active metal would be low under the exhaust gas conditions in the presence of high temperature steam. The present inventors have also found that a catalyst which uses an alkaline earth metal-containing crystalline silicate as a catalyst carrier and which supports Cu or other similar metals on the carrier inhibits the metal from separating from the crystal lattices at elevated temperatures and in the presence of steam; that is, the demetallization can be controlled. Thus the present inventors have developed a catalyst with excellent heat and steam resistance developed through the application of a crystalline silicate which incurs only a small possibility of dealuminization. Furthermore, the present inventors have also discovered that by employing a composite structure of a crystalline silicate catalyst, the demetallization in high temperature steam atmosphere can be prevented, and have developed new types of catalysts for the purification of exhaust gases containing nitrogen oxides, hydrocarbons, and carbon monoxide. A first aspect of this invention provides a catalyst for exhaust gas purification which comprises a crystalline silicate which in a dehydrated state has a chemical formula, in terms of the molar ratio of oxides, aR.sub.2 O.bMO.Al.sub.2 O.sub.3.cSiO.sub.2, wherein R is an alkali metal ion and/or hydrogen ion, M is an alkaline earth metal, Ca, Mg, Sr, or Ba, a =0-2, b=0.03-40, with the proviso that a+b>1, and c=11-3000 and which silicate has an X-ray diffraction pattern described in Table 1 hereinbelow, said crystalline silicate containing at least one metal chosen from Groups Ib and VIII of the periodic table. In the above chemical formula it is specified that a is 0 to 2 and a+b is more than one. This is because the components in these ranges permit the synthesis of the crystalline silicate as formulated. Also, the specified range of b being 0.03 to 40 is where the alkaline earth metal can function effectively. The further limitation of c being 11 to 3000 is based on the fact that if c is less than 11 the synthesis of the crystalline silicate is impossible and if c is more than 3000 the resulting catalyst according to the invention does not have adequate exhaust purification activity. Thus, the catalyst of the first aspect of the invention for exhaust gas purification is characterized by the use of a silicate containing an alkaline earth metal as a crystalline silicate which incurs only a limited possibility of removal of aluminum from the carrier. This silicate is produced through crystallization by hydrothermal synthesis, with the presence of an alkaline earth metal in the starting material mixture. TABLE 1______________________________________Lattice spacing (d value) Relative intensity______________________________________11.2 ± 0.3 VS10.0 ± 0.3 VS6.7 ± 0.2 W6.4 ± 0.2 M6.0 ± 0.2 M5.7 ± 0.2 W5.6 ± 0.2 M4.6 ± 0.1 W4.25 ± 0.1 M3.85 ± 0.1 VS3.75 ± 0.1 S3.65 ± 0.1 S3.3 ± 0.1 M3.05 ± 0.1 W3.0 ± 0.1 M______________________________________ VS: Very Strong S: Strong M: Moderate W: Weak For the synthesis of the crystalline silicate that contains an alkaline earth metal, the silica source to be used is water glass, silica sol, silica gel or the like. The alumina source to be chosen is aluminum nitrate, aluminum sulfate, sodium aluminate or the like. The alkali metal ion is, e.g., sodium oxide in water glass, sodium aluminate, sodium hydroxide. For alkaline earth metal ions, their acetates, nitrates, and chlorides may be used. As an alkaline earth metal calcium (Ca), magnesium (Mg), strontium (St), or barium (Ba) can be used. Further, as a crystallizing mineralizer tetrapropylammonium bromide or the like is used. The reaction mixture for the hydrothermal synthesis of the alkaline earth metal-containing crystalline silicate is made up with the following mixing ratios: SiO 2 /Al 2 O 3 =11 to 3000 (molar ratio); OH - /SiO 2 =0.01 to 10; H 2 O/SiO 2 =1 to 1000; tetrapropylammonium compound/SiO 2 =0 to 4; alkaline earth metal/Al (atomic ratio)=0.03 to 40. The crystalline silicate can be synthesized by heating the above mixture at 80° to 200° C. for about 1 to 200 hours with stirring, removing excess ions by water rinsing, drying, and then baking. The catalyst according to the first aspect of the invention is prepared by allowing the alkaline earth metal-containing crystalline silicate to support at least one metal in Groups Ib and VIII, e.g., copper or cobalt, either by way of ion exchange with the immersion of the silicate in an aqueous solution of such a metal or by impregnating the silicate with an aqueous solution of a salt of the metal, such as chloride or nitrate. Although the catalyst made in accordance with the invention is desired to have a honeycomb shape that permits the reduction of pressure loss, it may be pelletized instead. Such binder as silica sol or alumina sol in use for the molding of the catalyst has already been confirmed to have little adverse effect upon the catalyst performance. The catalyst of this first aspect for exhaust gas purification is adequately durable in automotive exhaust purification and other similar services with only little deterioration of activity in the presence of steam at 600° C. and even higher temperatures. The outstanding durability of the catalyst according to the first aspect of the invention is attributable to the use of an alkaline earth-containing silicate as a carrier. The alkaline earth contained in the silicate functions to decrease the number of strongly acidic points in the silicate which would otherwise accelerate the dealuminization. On the other hand, it causes little change in the catalytic activities for NO adsorption and the activation of hydrocarbons. Since the dealuminization is thus avoided, the Group Ib or VIII metal or metals that are active can be stably supported by the silicate carrier. A second aspect of this invention provides a catalyst for exhaust gas purification, comprising a crystalline silicate which in a dehydrated state has a chemical formula, (1±0.4)R.sub.2 O.[aM.sub.2 O.sub.3.bAl.sub.2 O.sub.3 ].cMeO.ySiO.sub.2, wherein R is an alkali metal ion and/or hydrogen ion, M is at least one element selected from the group consisting of Group VIII elements, rare earth elements, titanium, vanadium, chromium, niobium, and antimony, Me is an alkaline earth element, a+b=1.0, a>0, b>0, y/c>12, and y>12, said crystalline silicate containing at least one metal selected from Zn, Mn, Cr, and the elements in Groups Ib and VIII of the periodic table. The alkaline earth metal-containing crystalline silicate is prepared by mixing sources of silica, alkaline earth metal, alkali metal, transition metal, and aluminum with water and a quaternary alkylammonium salt such as tetrapropylammonium bromide, or an alcohol amine, alkylamine or the like, and then holding this reaction mixture for a period and at a temperature adequate for forming a crystalline silicate. The silica source to be used may be water glass, silica sol, silica gel or the like. The alkaline earth metal source may be an acetate, nitrate, chloride, or the like of Ca, Mg, St, or Ba. The alkali metal is, e.g., sodium in water glass, sodium hydroxide, or potassium hydroxide. The aluminum source may be sodium aluminate, aluminum nitrate, aluminum sulfate, or the like. Transition metal sources include the Group VIII elements, such as Fe, Ni, Co, Rh, Ru, and Pd, rare earth elements, such as La and Ce, as well as Ti, V, Cr, Nb, and Sb. Such a source of transition metals may be used in the form of, e.g., a sulfate, nitrate, or chloride as a starting material. The catalyst is prepared by adding the chloride or nitrate of Cu, Co, Ni, Zn, Fe, Cr, or Mn to the alkaline earth metal-containing crystalline silicate either through impregnation or ion exchange with an aqueous solution of their salt. The catalyst according to the second aspect of the invention is characterized in that it is prepared by allowing an alkaline earth metal to be present in the reaction mixture at the time of crystalline silicate synthesis. Presumably, the alkaline earth metal incorporated and stabilized in the lattice of the silicate crystal in this way helps improve the catalyst durability. A third aspect of this invention provides a catalyst for exhaust gas purification comprising a composite crystalline silicate having an X-ray diffraction pattern described in Table 1 above, the composite crystalline silicate being formed by growing a crystalline silicate made from Si and O over a mother crystal of a crystalline silicate synthesized in advance, the mother crystal being represented, in a dehydrated state and in terms of the molar ratio of oxides, by the following chemical formula: (1±0.6 )R.sub.2 O.[aM.sub.2 O.sub.3.bAl.sub.2 O.sub.3 ].ySiO.sub.2, wherein R is an alkali metal ion and/or hydrogen ion, M is an ion of at least one element selected from the group consisting of Group VIII elements, rare earth elements, titanium, vanadium, chromium, niobium, antimony, and gallium, a≦0, b≦0, a+b=1, and y>12, said mother crystal having an X-ray diffraction pattern described in Table 1 above, the crystalline silicate grown over the mother crystal having the same crystalline structure as the mother crystal, and the composite crystalline silicate containing at least one metal chosen from Groups Ib and VIII of the periodic table. The mother crystal to be used in the third aspect of the present invention is synthesized under the following conditions: SiO 2 /(M 2 O 3 +Al 2 O 3 ): 12-3000 (preferably 20-200 ) OH - /SiO 2 : 0-1.0 (preferably 0.2-0.8) H 2 O/SiO 2 : 2-1000 (preferably 10-200) Organonitrogen compound/(M 2 O 3 +Al 2 O 3 ): 0-200 (preferably 0-50) M signifies one or more elements chosen from Group VIII elements, rare earth elements, titanium, vanadium, chromium, niobium, antimony, and gallium, and the organonitrogen compound when used may be tetrapropylammonium bromide or the like. The crystalline silicate used as the mother crystal can be synthesized by heating a mixture of the above materials at a temperature and for a time period sufficient for producing a crystalline silicate. The temperature for hydrothermal synthesis is in the range of 80° to 300° C., preferably 130° to 200° C., and the hydrothermal synthesis may be carried out for 0.5 to 14 days, preferably 1 to 10 days. The pressure is not specifically limited, but desirably the synthesis is carried out under the mixture's own pressure. The hydrothermal synthesis reaction is effected by heating the material mixture to a desired temperature and, with stirring where necessary, continued until a crystalline silicate forms. Following the crystallization, the reaction mixture is cooled down to room temperature, filtered, rinsed with water, and separated. Usually, the product is further dried at 100° C. or above for about 5 to 24 hours. The term "composite crystalline silicate" as used herein means a composite crystalline silicate of a structure formed by first synthesizing a crystalline silicate in the aforesaid manner as a mother crystal and then allowing a crystalline silicate (to be called "silicalite" hereinafter) which comprises Si and O and has the same structure as the mother crystal to grow thereon. The crystalline silicate serving as the mother crystal is desirably one which is represented, in a dehydrated state and in terms of the molar ratio of oxides, by the following chemical formula: (1±0.6)R.sub.2 O.[aM.sub.2 O.sub.3.bAl.sub.2 O.sub.3 ].ySiO.sub.2, wherein R is an alkali metal ion and/or hydrogen ion, M is an ion of at least one element selected from the group consisting of Group VIII elements, rare earth elements, titanium, vanadium, chromium, niobium, antimony, and gallium, a≧0, b≧0, a+b=1, and y>12, said crystalline silicate having an X-ray diffraction pattern shown in Table 1 above. One method for the crystal growth of silicalite on the outer surface of the crystalline silicate serving as the mother crystal is hydrothermal synthesis. For the crystal growth of silicalite on the outer surface of the mother crystal by hydrothermal synthesis, water glass, silica sol or the like is employed as a silica source. The alkali metal ion to be used is, e.g., sodium oxide or sodium hydroxide in water glass, and the crystallizing mineralizer is, e.g., tetrapropylammonium bromide. The proportion of the silicalite to be grown as crystal with respect to the mother crystal crystalline silicate is desirably, in terms of the silicalite/mother crystal weight ratio, from 0.01 to 100 for the synthesis. Also, as a prerequisite for the crystal growth of silicalite on the mother crystal, the mixing ratios of the materials should be: OH - /SiO 2 =0.01 to 10, H 2 O/SiO 2 =1 to 1000, and organic matter (e.g., tetrapropylammonium compound)/SiO 2 =0 to 10. The synthesis procedure consists of adding finely powdered mother crystals to the above mixture, stirring the whole mixture homogeneously, heating it with stirring at 80 to 200° C. for 1 to 200 hours, removing excess ions by water rinsing, drying, and baking. In this way a composite crystalline silicate according to the third aspect of the present invention is obtained. The catalyst is prepared by immersing the composite crystalline silicate in an aqueous solution of a salt of a Group Ib or VIII metal, e.g., copper or cobalt, and allowing the silicate to support the metal ion by ion exchange or by impregnation with an aqueous solution of a metal salt, such as chloride or nitrate. In the third aspect of the invention, the use of a silicalite-covered composite crystalline silicate improves the durability of the resulting catalyst for the following reason. In exhaust emissions present are such gases as NO, CO, hydrocarbons, H 2 O (steam), and O 2 . The exhaust is purified at the active reaction sites of the catalyst while, at the same time, the presence of high temperature H 2 O tends to cause metals to separate from the silicate (demetallization). However, the coating of silicalite, which is hydrophobic by nature, makes it difficult for H 2 O alone to permeate deep into the crystalline silicate. As a consequence, the H 2 O concentrations become low around the active reaction sites in the catalyst, and the demetallization is inhibited. A fourth aspect of this invention provides a catalyst for exhaust gas purification comprising a composite crystalline silicate having an X-ray diffraction pattern shown in Table 1 above, the composite crystalline silicate being formed by growing a crystalline silicate made from Si and 0 over a mother crystal of a crystalline silicate synthesized in advance, said mother crystal is represented, in a dehydrated state and in terms of the molar ratio of oxides, by the following chemical formula: (1±0.6)R.sub.2 O.[aM.sub.2 O.sub.3.bAl.sub.2 O.sub.3 ].cMeO.ySiO.sub.2, wherein R is an alkali metal ion and/or hydrogen ion, M is at least one element selected from the group consisting of Group VIII elements, rare earth elements, titanium, vanadium, chromium, niobium, antimony, and gallium, Me is an alkaline earth element, a≧0, b≧0, c≧0, a+b=1, y/c>12, and y>12, the mother crystal having an X-ray diffraction pattern shown in Table 1 above, the crystalline silicate grown over the mother crystal having the same crystalline structure as the mother crystal, and the composite crystalline silicate containing at least one metal chosen from Groups Ib and VIII of the periodic table. The mother crystal to be used in the present invention can be synthesized under the following conditions: SiO 2 /(M 2 O 3 +Al 2 O 3 ): 12-3000 (preferably 20-200) SiO 2 /MeO: 12-∞(preferably 20-10000) OH - /SiO 2 : 0-10 H 2 O/SiO 2 : 2-1000 (preferably 10-200) Organonitrogen compound/(M 2 O 3 +Al 2 O 3 ): 0-1000 (preferably 0-50) M is at least one element selected from the group consisting of Group VIII elements, rare earth elements, titanium, vanadium, chromium, niobium, antimony, and gallium, Me is an alkaline earth metal, and the organonitrogen compound when used may be tetrapropylammonium bromide or the like. The crystalline silicate used as the mother crystal is synthesized by heating a mixture of the above materials at a temperature and for a time period sufficient for producing a crystalline silicate. The temperature for hydrothermal synthesis is in the range of 80° to 300° C., preferably 130° to 200° C., and the hydrothermal synthesis is carried out for 0.5 to 14 days, preferably 1 to 10 days. The pressure is not specifically limited, but desirably the synthesis is carried out under the mixture's own pressure. The hydrothermal synthesis reaction is effected by heating the material mixture to a desired temperature and, with stirring where necessary, kept on until a crystalline silicate forms. Following the crystallization, the reaction mixture is cooled down to room temperature, filtered, rinsed with water, and separated. Usually, the product is further dried at 100° C. or above for about 5 to 24 hours. The term "composite crystalline silicate" as used herein means a composite crystalline silicate of a structure formed by first synthesizing a crystalline silicate in the aforesaid manner as a mother crystal and then allowing a crystalline silicate (to be called "silicalite" hereinafter) which comprises Si and O and has the same structure as the mother crystal to grow thereon. The crystalline silicate serving as the mother crystal is desirably one which is represented, in a dehydrated state and in terms of the molar ratio of oxides, by the following chemical formula: (1±0.6)R.sub.2 O.[aM.sub.2 O.sub.3.bAl.sub.2 O.sub.3 ].cMeO.ySiO.sub.2, wherein R is an alkali metal ion and/or hydrogen ion, M is the ion of at least one element selected from the group consisting of Group VIII elements, rare earth elements, titanium, vanadium, chromium, niobium, antimony, and gallium, Me is an alkaline earth element, a≧0, b≧0, c≧0, a+b=1, y/c>12, and y>12, said crystalline silicate having an X-ray diffraction pattern shown in Table 1 above. One method for the crystal growth of silicalite on the outer surface of the crystalline silicate serving as the mother crystal is hydrothermal synthesis. For the crystal growth of silicalite on the outer surface of the mother crystal by hydrothermal synthesis, water glass, silica sol or the like is employed as a silica source. The alkali metal ion to be used is, e.g., sodium oxide or sodium hydroxide in water glass, and the crystallizing mineralizer is, e.g., tetrapropylammonium bromide. The proportion of the silicalite to be grown as crystal with respect to the crystalline silicate as the mother crystal is desirably, in terms of the silicalite/mother crystal weight ratio, from 0.01 to 100 for the synthesis. Also, as a prerequisite for the crystal growth of silicalite on the mother crystal, the mixing ratios of the materials should be: OH - /SiO 2 =0.01 to 10, H 2 O/SiO 2 =1 to 1000, and organic matter (e.g., tetrapropylammonium compound)/SiO 2 =0 to 10. The synthesis procedure consists of adding finely powdered mother crystals to the above mixture, stirring the whole mixture homogeneously, heating it with stirring at 80 to 200° C. for 1 to 200 hours, removing excess ions by water rinsing, drying, and baking. In this way a composite crystalline silicate according to the present invention is obtained. The catalyst is prepared by immersing the composite crystalline silicate in an aqueous solution of a salt of a Group Ib or VIII metal, e.g., copper or cobalt, and allowing the silicate to support the metal ion by ion exchange or by impregnation with an aqueous solution of a metal salt, such as chloride or nitrate. The use of a silicalite-covered composite crystalline silicate improves the durability of the resulting catalyst for the following reason. In exhaust emissions are present such gases as NO, CO, hydrocarbons, H 2 O (steam), and O 2 . The exhaust is purified at the active reaction sites of the catalyst while, at the same time, the presence of high temperature H 2 O tends to cause metals to separate from the silicate (demetallization). However, the coating of silicalite, which is hydrophobic by nature, makes it difficult for H 2 O alone to permeate deep into the crystalline silicate. As a consequence, the H 2 O concentrations around the active reaction sites in the catalyst are low and the demetallization is inhibited. Moreover, in the catalyst according to the fourth aspect of the invention, the alkaline earth element contained in the mother crystal weakens the strongly acidic sites in the silicate which would otherwise promote the removal of metal from the resulting catalyst and thereby inhibits the demetallization in the presence of high-temperature steam. As discussed in connection with the first to fourth aspects above, the catalyst for exhaust gas purification in accordance with the invention is highly durable and stable. It is useful as a catalyst for purifying exhaust gases from lean-burn gasoline engines and diesel engines of motor vehicles. In the following the present invention will be described in further detail with reference to a number of embodiments for this invention and comparative examples for conventional catalyst. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The first aspect of the invention will now be described in detail by way of Examples 1 to 3 and Comparative Example 1. EXAMPLE 1 Catalysts for describing the first aspect of this invention were prepared in the following way. Synthesis of alkaline earth metal-containing silicate 1A A solution prepared by dissolving 395.5 g of aluminum nitrate and 94.4 g of calcium acetate in 6552 g of water was designated solution 1A. Solution 1B was prepared by dissolving 4212 g of water glass sold as "Cataloid SI-30" (a product of Catalysts & Chemicals Industries Co., Japan, contg. 30.5% SiO 2 and 0.42% Na 2 O) in 2808 g of water. Solution 1B was added to solution 1A with vigorous stirring. Next, a solution of 234 g sodium hydroxide in 1404 g water and then a solution of 568.6 g tetrapropylammonium bromide (TPABr) in 2106 g water were added. Stirring was continued for about 10 minutes, and an aqueous gel mixture resulted. The molar ratios of the components were: SiO 2 /Al 2 O 3 =40 and SiO 2 /CaO=40. This aqueous gel mixture was charged into an autoclave having a capacity of 20 liters and hydrothermally treated at the charge's own pressure and at 160° C. for 72 hours with stirring (at 200 rpm). Following the treatment, the reaction product was centrifuged for solid-liquid separation. The solid matter was thoroughly washed with water and dried at 120° C. for 5 hours in the air. It was then baked at 500° C. for 5 hours. The Ca-containing crystalline silicate thus obtained is herein referred to as silicate 1A. Synthesis of alkaline earth metal-containing silicates 1B-1N The procedure described above for the synthesis of the alkaline earth metal-containing silicate 1A was repeated except for changes in the alkaline earth salts used as an ingredient and in compositional formulation to obtain various alkaline earth metal-containing silicates 1B to 1N. The proportions of ingredients are listed in Table 2 below. Preparation of catalysts Alkaline earth metal-containing silicates 1A to 1N were subjected to copper ion exchange by immersion in a 0.04M aqueous copper acetate with stirring, and after 24-hour stirring at room temperature they were rinsed. This cycle of copper ion exchange was repeated three times each with a fresh supply of the solution. Final rinsing and drying gave powder catalysts 1a to 1n. To 100 parts of each of the powder catalysts added as binders were 3 parts of alumina sol, 55 parts of silica sol, and 230 parts of water. The mixtures upon thorough stirring afforded slurries for wash coating. Divided portions of cordierite type monolithic substrates (with a 400-cell lattice pattern) were separately dipped in the slurries and taken out, excess slurries were blown away, and then dried at 200° C. The coating weighed 200 g per liter of the substrate. The coated substrates are designated as honeycomb catalysts 1A to 1N. TABLE 2__________________________________________________________________________ "Cataloid" Alkaline earch Charge Conditions forSilicate SI-30 Al(NH.sub.3).sub.2.9H.sub.2 O NaOH TPABr metal salt composition hydrothermalNo. (g) (g) (g) (g) Type (g) SiO.sub.2 /Al.sub.2 O.sub.3 SiO.sub.2 /MO synthesis__________________________________________________________________________1A 4212 395.5 234 568.6 Ca(CH.sub.3 COO).sub.2.H.sub. 94.4 40 M:Ca 40 160° C. × 72 hr1B " " " " Mg(CH.sub.3 COO).sub.2.4H.sub.2 O 114.7 40 M:Mg 40 "1C " " " " Sr(CH.sub.3 COO).sub.2.1/2H.sub.2 O 113.0 40 M:Sr 40 "1D " " " " Ba(CH.sub.3 COO).sub.2.H.sub.2 O 143.5 40 M:Ba 40 "1E " " " " Ca(CH.sub.3 COO).sub.2.H.sub.2 O 47.2 40 M:Ca 80 "1F " " " " Ca(CH.sub.3 COO).sub.2.H.sub.2 O 188.8 40 M:Ca 20 "1G " " " " Ca(NO.sub.3).sub.2.4H.sub.2 O 126.5 40 M:Ca 40 "1H " " " " Ba(NO.sub.3).sub.2. 104.6 40 M:Ba 40 "1I " " " 94.6 Ca(CH.sub.3 COO).sub.2.H.sub.2 O 94.4 40 M:Ca 40 "1J " 197.8 " 568.6 Ca(CH.sub.2 COO).sub.2.H.sub.2 O 94.4 80 M:Ca 40 "1K " " " " CaCl.sub.2.2H.sub.2 O 78.8 80 M:Ca 40 "1L " " " " Sr(CH.sub.3 COO).sub.2.1/2H.sub.2 O 113.0 80 M:Sr 40 "1M " " " " Ba(CH.sub.3 COO).sub.2.H.sub.2 O 143.5 80 M:Ba 40 "1N " " " " Mg(CH.sub.3 COO).sub.2.4H.sub.2 O 114.7 80 M:Mg 40 "1O 4212 395.5 234 568.6 -- 40 -- 160° C. × 72 hr1P " 197.8 " " -- 80 -- "__________________________________________________________________________ EXAMPLE 2 Divided portions of silicate 1A obtained in Example 1 were immersed with agitation in 0.04M aqueous solutions of cuptic chloride, cobalt chloride, nickel chloride, ferric chloride, and silver nitrate, and in the same way as described in Example 1, powder catalysts 1O to 1S were prepared. These powder catalysts were supported by monolithic substrates in the manner described in Example 1, and honeycomb catalysts 1O to 1S were obtained. EXAMPLE 3 Silicate 1A prepared in Example 1, with the addition of a binder, was applied to a cordieritc type monolithic substrate to form a coating. Divided portions of the coated monolithic substrate were separately immersed for impregnation over a one-hour period in a solution of cuprous chloride in hydrochloric acid (26.8 g in 200 cm 3 of HCl), aqueous cupric chloride solution (46.1 g in 200 cm 3 of water), aqueous cobalt chloride (64.4 g in 200 cm 3 of water), aqueous nickel chloride (64.4 g in 200 cm 3 of water), aqueous solution mixture of cupric chloride and cobalt chloride (23.1 g of CuCl 2 .2H 2 O and 32.2 g of CoCl 2 .6H 2 O in 200 cm 3 of water), and aqueous solution mixture of nickel chloride and cobalt chloride (32.2 g of NiCl 2 .2H 2 O and 32.2 g of CoCl 2 .6H 2 O in 200 cm 3 of water), respectively. The solutions left on the walls of the substrates were wiped off, and the coated substrates were dried at 200° C. A 12-hour purging in a nitrogen atmosphere at 500° C. yielded honeycomb catalysts 1T to 1Y. COMPARATIVE EXAMPLE 1 Two types of crystalline silicates were synthesized by the same method as described in Example 1 with the exception that no alkaline earth metal was added. The material proportions of these silicates, designated as 1O and 1P, are also given in Table 2. These silicates 1O and 1P were subjected to Cu ion exchange in the same manner as for the catalyst preparation in Example 1 to obtain powder catalysts 1t and 1u. Likewise monolithic substrates were coated with them to give honeycomb catalysts 1Z and 1ZA. The details of thus obtained honeycomb catalysts 1A to 1ZA are summarized in Table 3. EXPERIMENT 1 Honeycomb catalysts 1A to 1ZA prepared in Examples 1 to 3 and in Comparative Example 1 were tested for the evaluation of their activities. The conditions for activity evaluation were as follows. Gas composition NO=400 ppm; CO=1000 ppm; C 2 H 4 =1000 ppm; C 3 H 6 =340 ppm; O 2 =8%; CO 2 =10%; H 2 O=10%; the remainder=N 2 ; GHSV=30000 hr -1 ; catalyst shape=15 mm×15 mm×60 mm (144 cells); reaction temperature=350° C. The denitration rates of the catalysts in the initial state at 450° C. are given in Table 4. EXPERIMENT 2 As a durability test the catalysts were forced to deteriorate with the supply of a gaseous mixture consisting of 10% H 2 O and the balance N 2 gas at a GHSV of 30000 hr -1 for 24 hours. The forcibly deteriorated honeycomb catalysts 1A to 1ZA were evaluated for their activities under the same conditions as used in Experiment 1. The results are also shown in Table 4. As Table 4 indicates, honeycomb catalysts 1A to 1Y prepared using alkaline earth metal-containing silicates had high denitration activities after the forced deterioration as well as in the initial state, proving that they were durable. Table 4 also indicates that the ordinary silicate catalysts (honeycomb catalysts 1Z and 1ZA) showed substantial reductions in activity after the forced deterioration, revealing that they were less durable. TABLE 3__________________________________________________________________________ Qty of active substance supportedHoneycomb Powder (mmol per gram Type of silicatecatalyst No. catalyst No. of silicate) No. SiO.sub.2 /Al.sub.2 O.sub.3 SiO.sub.2 /MO__________________________________________________________________________1A 1a Cu (0.55) 1A 40 M:Ca 401B 1b Cu (0.5) 1B 40 M:Mg 401C 1c Cu (0.55) 1C 40 M:Sr 401D 1d Cu (0.5) 1D 40 M:Ba 401E 1e Cu (0.5) 1E 40 M:Ca 801F 1f Cu (0.45) 1F 40 M:Ca 201G 1g Cu (0.4) 1G 40 M:Ca 401H 1h Cu (0.45) 1H 40 M:Ba 401I 1i Cu (0.5) 1I 40 M:Ca 401J 1j Cu (0.4) 1J 80 M:Ca 401K 1k Cu (0.35) 1K 80 M:Ca 401L 1l Cu (0.45) 1L 80 M:Sr 401M 1m Cu (0.4) 1M 80 M:Ba 401N 1n Cu (0.35) 1N 80 M:Mg 401O 1o Cu (0.55) 1A 40 M:Ca 401P 1p Co (0.5) 1A 40 M:Ca 401Q 1q Ni (0.55) 1A 40 M:Ca 401R 1r Fe (0.35) 1A 40 M:Ca 401S 1s Ag (0.8) 1A 40 M:Ca 401T -- Cu (0.8) 1A 40 M:Ca 401U -- Cu (0.8) 1A 40 M:Ca 401V -- Co (0.8) 1A 40 M:Ca 401W -- Ni (0.8) 1A 40 M:Ca 401X -- Cu(0.4)Co(0.4) 1A 40 M:Ca 401Y -- Ni(0.4)Co(0.4) 1a 40 M:Ca 401Z 1t Cu (0.6) 1O 40 --1ZA 1u Cu (0.4) 1P 40 --__________________________________________________________________________ TABLE 4______________________________________ After forced Initial activity deteriorationHoneycomb (ηNOx %) (ηNOx %)Catalyst No. 350° C. 450° C. 350° C. 450° C.______________________________________1A 42 39 37 391B 41 40 35 391C 38 42 33 401D 41 39 36 381E 42 39 38 391F 44 41 38 421G 45 41 40 411H 42 43 38 411I 45 41 39 401J 46 43 38 411K 43 41 39 401L 42 39 38 391M 40 40 36 371N 41 42 35 381O 42 40 34 391P 41 39 38 401Q 43 41 36 391R 28 29 28 291S 31 31 30 281T 45 40 35 401U 44 39 39 401V 46 41 36 391W 45 40 35 391X 43 39 36 381Y 41 38 35 381Z 41 38 8 181ZA 42 39 7 17______________________________________ As for the purification activity against CO and hydrocarbons, honeycomb catalysts 1A to 1Y according to the first aspect of the invention showed little changes in activity from the initial stage till after the forced deterioration. They all achieved 100% removal of those pollutants at both 350° C. and 450° C. Comparative honeycomb catalysts 1Z and 1ZA also exhibited initial activities of 100% CO and hydrocarbon removal at the two temperature levels. After the forced deterioration, however, honeycomb catalyst 1Z showed much lower CO removal rates at 350° C. and 450° C. of 15% and 60%, respectively. Its hydrocarbon removal rates at the two temperature levels dropped to 45% and 80%. At 350° C. and 450° C, honeycomb catalyst 1ZA too showed reduced CO removal rates of 10% and 50% and hydrocarbon removal rates of 35% and 70%, respectively. The second aspect of the invention will now be described in more detail by way of Example 4 and Comparative Example 2. EXAMPLE 4 Synthesis of alkaline earth metal-containing silicate 2A A solution prepared by dissolving 5616 g of water glass #1 (contg. 30 wt % SiO 2 ) in 5429 g of water is referred to as solution 2A. Into 4175 g of water were dissolved 453.6 g of aluminum sulfate (Al 2 (SO 4 ) 3 .17H 2 O), 94.6 g of ferric chloride (FeCl 3 .6H 2 O), 153.3 g of calcium chloride (CaCl 2 .6H 2 O), 262 g of sodium chloride, and 2020 g of concentrated hydrochloric acid. The resulting solution is designated as solution 2B. Solutions 2A and 2B were gradually mixed and sufficiently stirred to form a precipitate, thus preparing a slurry with pH 8.0. This slurry was charged into an autoclave and, with the addition of 500 g tetrapropylammonium bromide, the mixture was kept at 160° C. for 72 hours for crystallization. The crystalline product was filtered, rinsed, dried, and baked in air at 500° C. for 3 hours, and crystalline silicate 2A resulted. Synthesis of alkaline earth metal-containing crystalline silicates 2B, 2C, and 2D The procedure for the synthesis of silicate 2A was repeated with the exception that calcium chloride (as 6H 2 O salt) was replaced by 142.3 g of magnesium chloride (as 6H 2 O salt), 186.6 g of strontium chloride (as 6H 2 O salt), or 170.9 g of barium chloride (as 2H 2 O salt) to obtain crystalline silicates 2B, 2C, and 2D, respectively. Preparation of catalysts With the addition of a binder, powders of crystalline silicates 2A to 2D were applied to cordierite monolithic substrates (meshed with 400 cells per square inch). The coated substrates were immersed in a 4M aqueous NH 4 Cl solution at 80° C. for 24 hours to effect NH 4 ion exchange. The ion exchange was followed by rinsing, drying, and baking at 500° C. for 3 hours to convert the coated crystalline silicates to proton type silicates. The monolithic catalysts so obtained were then separately dipped separately in an aqueous hydrochloric acid solution of CuCl and aqueous solutions of CoCl 2 , NiCl 2 , ZnCl 2 , FeCl 3 , and MnCl 2 . Excess liquid was wiped off from the substrate walls, and the catalysts were dried at 200° C. Purging in an N 2 atmosphere at 500° C. for 12 hours gave catalysts C1 to C28 as listed in Table 5 below. The quantity of each metal supported by the crystalline silicate was 0.8 mmol/g. COMPARATIVE EXAMPLE 2 As a comparative example, crystalline silicate 2E was obtained by the same procedure for the synthesis of crystalline silicate 2A but without the addition of calcium chloride. Then, catalysts R1 to R7 were prepared for comparison purposes are prepared using this crystalline silicate 2E in the same way as with the preparation of catalysts C1 to C28 with the supported metal listed in Table 5 below. Also, divided portions of the monolithic substrate coated with silicate 2A were converted to the proton type in the manner described above and then were subjected to ion exchange separately with aqueous solutions of the chlorides of Ca, Mg, Sr, and Ba. After water rinsing, drying, and dipping in aqueous hydrochloric acid solution of CuCl in the same way as above, catalysts R8 to R11 were obtained as comparative examples. EXPERIMENT 3 The monolithic catalysts prepared as above were tested for their catalytic performance before and after use in the treatment of a gas consisting of 10% H 2 O and the balance N 2 at 700° C. and at a GHSV of 30000 Hr -1 for 24 hours. Their performance was determined under the following conditions. Testing conditions NO: 400 ppm CO: 1000 ppm C 2 H 4 : 1000 ppm C 3 H 6 : 340 ppm O 2 : 8% CO 2 : 10% H 2 O: 10% N 2 : balance GHSV: 30000 hr -1 The denitration rates at 350° C. and 450° C. are given in Table 6. TABLE 5______________________________________Catalysts prepared Crystal- Alkaline earthCatalyst line metal in crystalline MetalNo. silicate silicate supported______________________________________ExampleC1 2A Ca CuC2 2A Ca CoC3 2A Ca NiC4 2A Ca ZnC5 2A Ca FeC6 2A Ca CrC7 2A Ca MnC8 2B Mg CuC9 2B Mg CoC10 2B Mg NiC11 2B Mg ZnC12 2B Mg FeC13 2B Mg CrC14 2B Mg MnC15 2C Sr CuC16 2C Sr CoC17 2C Sr NiC18 2C Sr ZnC19 2C Sr FeC20 2C Sr CrC21 2C Sr MnC22 2D Ba CuC23 2D Ba CoC24 2D Ba NiC25 2D Ba ZnC26 2D Ba FeC27 2D Ba CrC28 2D Ba MnComparativeExampleR1 2E None CuR2 2E " CoR3 2E " NiR4 2E " ZnR5 2E " FeR6 2E " CrR7 2E " MnR8 2E " Cu + CaR9 2E " Cu + MgR10 2E " Cu + SrR11 2E " Cu + Ba______________________________________ TABLE 6______________________________________ Denitration rate (%) Before After treatment treatmentCatalyst No. 350° C. 400° C. 350° C. 400° C.______________________________________C1 41 40 37 40C2 47 41 42 41C3 47 39 42 39C4 32 40 29 40C5 30 29 29 29C6 28 25 25 25C7 25 33 21 33C8 40 39 36 40C9 46 40 42 39C10 45 40 41 41C11 33 41 30 41C12 30 28 28 28C13 29 24 26 24C14 24 34 21 34C15 40 42 37 42C16 46 40 41 40C17 45 41 40 40C18 33 41 30 41C19 31 29 27 28C20 29 25 25 25C21 23 32 21 31C22 39 40 35 40C23 47 41 42 41C24 46 40 41 40C25 32 40 30 41C26 29 27 26 28C27 28 24 26 24C28 24 31 23 30R1 41 39 10 20R2 46 40 8 20R3 46 41 9 21R4 33 39 11 19R5 30 29 9 15R6 27 24 8 12R7 23 31 10 18R8 38 41 12 23R9 39 40 10 22R10 40 41 7 19R11 38 39 10 20______________________________________ Catalysts C1 to C28 according to the second aspect of the present invention were found to be clearly superior to comparative catalysts R1 to R11 in denitration after the treatment of a gaseous mixture with 10% H 2 O at 700° C., and it is now obvious that the catalysts of the second aspect of the invention is excellently durable and useful as a catalyst for the treatment of exhaust gases. The third aspect of the present invention will now be described in detail by way of Examples 5 to 8 and Comparative Example 3. EXAMPLE 5 Synthesis of mother crystal 3A A solution of 5616 g of water glass #1 (contg. 30% SiO 2 ) in 5429 g of water is prepared and referred to as solution 3A. Meanwhile 718.9 g of aluminum sulfate, 110 g of ferric chloride, 262 g of sodium chloride, and 2020 g of concentrated hydrochloric acid are dissolved in 4175 g of water, and the solution is designated as solution 3B. Solutions 3A and 3B are fed at a predetermined ratio, and the mixture is caused to precipitate. Thorough agitation yields a slurry of pH 8.0. This slurry is charged into a 20-liter autoclave and, with the addition of 500 g tetrapropylammonium bromide, the mixture is subjected to hydrothermal synthesis at 160° C. for 72 hours. The synthesis is followed by water rinsing, drying, and baking at 500° C. for 3 hours to obtain crystalline silicate 3A. This crystalline silicate is represented, in terms of the molar ratio of the oxides (excluding crystal water), by the compositional formula: 0.5Na.sub.2 O.0.5H.sub.2 O.[0.8Al.sub.2 O.sub.3.0.2Fe.sub.2 O.sub.3 ].25SiO.sub.2 and has a crystal structure according to an X-ray diffraction analysis as shown in Table 1 above. Synthesis of composite crystalline silicate A One thousand grams of mother crystal A (crystalline silicate A) in a finely powdered state is added to 2160 g of water. With the further addition of 4590 g of colloidal silica (contg. 20% SiO 2 ), the mixture is thoroughly stirred, and the resulting solution is designated solution 3a. In the meantime 105.8 g of sodium hydroxide is dissolved in 2008 g of water to prepare solution 3b. While solution 3a is kept under agitation, solution 3b is slowly added drop-wise into solution 3a to form a precipitate and obtain a slurry. This slurry is placed in an autoclave and a solution of 568 g tetrapropylammonium bromide in 2106 g of water is added. Inside the autoclave hydrothermal synthesis is carried out at 160° C. for 72 hours (with stirring at 200 rpm). After the stirring, the synthesis product is rinsed, dried, and baked at 500° C. for 3 hours to yield composite crystalline silicate 3A. Preparation of catalysts The composite crystalline silicate 3A was subjected to copper ion exchange by immersion in a 0.04M aqueous copper acetate solution at 30° C. with stirring. After 24-hour stirring, it was rinsed, and this cycle was repeated to conduct the copper ion exchange with the aqueous solution three times. Final rinsing and drying gave powder catalyst 3a. To 100 parts of powder catalyst 3a added as binders were 3 parts of alumina sol, 55 parts of silica sol (contg. 20% SiO 2 ), and 200 parts of water. The mixture on thorough stirring afforded a slurry for wash coating. A monolithic substrate (with a 400-cell lattice pattern) for cordierite was dipped in the slurry and taken out, excess slurry was blown away, and then dried at 200° C. The coating so supported weighed 200 g per liter of the substrate, and this coated matter is designated as honeycomb catalyst 3A. EXAMPLE 6 Mother crystals 3B to 3L were prepared by repeating the procedure for the synthesis of the mother crystal 3A in Example 5 with the exception that the ferric chloride was replaced by the chlorides of cobalt, ruthenium, rhodium, lanthanum, cerium, titanium, vanadium, chromium, antimony, gallium, or niobium, respectively, each in the same molar amount as Fe 2 O 3 in terms of equivalency as oxide. The compositions of these mother crystals are represented, as the molar ratio of the oxides (in the dehydrated state), by the formula: 0.5Na.sub.2 O0.5H.sub.2 O.(0.2M.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3).25SiO.sub.2, wherein M is Co, Ru, Rh, La, Ce, Ti, V, Cr, Sb, Ga, or Nb, constituting mother crystals 3B to 3L, respectively. In the same manner as with mother crystal 3A but without the addition of the ferric chloride, mother crystal 3M was obtained. These mother crystals 3B to 3M were finely powdered and used in place of mother crystal 3A in the synthesis of the crystalline silicate in Example 5. Repeated runs of hydrothermal synthesis using the autoclave gave laminar composite crystalline silicates 3B to 3M. Using these crystalline silicates 3B to 3M, the procedure of Example 5 for the preparation of a catalyst was repeated, and powder catalysts 3b to 3m were obtained. These powder catalysts were used to coat monolithic substrates of cordierite, in the same way as in the preparation of catalyst in Example 5, and honeycomb catalysts 3B to 3M were obtained. EXAMPLE 7 Divided portions of composite crystalline silicate 3A obtained in Example 5 were immersed with agitation in 0.04M aqueous solutions of cupric chloride, cobalt chloride, nickel chloride, ferric chloride, and silver nitrate at 60° C. for ion exchange with the respective metals. Then, in the same way as described in Example 5, powder catalysts 3n to 3r were prepared. These powder catalysts were supported by monolithic substrates in the manner described in Example 5, and honeycomb catalysts 3N to 3R were obtained. EXAMPLE 8 Composite crystalline silicate A prepared in Example 5 was immersed in a 4N aqueous NH 4 Cl solution at 80° C. and was stirred for 24 hours for NH 4 ion exchange. Following the ion exchange, the product was rinsed, dried at 100° C. for 24 hours, and baked at 500° C. for 3 hours to give H type crystalline silicate 3A. With the addition of a binder, this silicate 3A was applied to a cordierite type monolithic substrate as a coating. Divided portions of the coated monolithic substrate were separately immersed for impregnation over a one-hour period in a cuprous chloride solution in hydrochloric acid (26.8 g in 200 cm 3 of HCl), aqueous cupric chloride solution (46.1 g in 200 cm 3 of water), aqueous cobalt chloride solution (64.4 g in 200 cm 3 of water), aqueous nickel chloride solution (64.4 g in 200 cm 3 of water), aqueous solution mixture of cupric chloride and cobalt chloride (23.1 g CuCl 2 .2H 2 O and 32.2 g CoCl 2 .6H 2 O in 200 cm 3 of water), and aqueous solution mixture of nickel chloride and cobalt chloride (32.2 g NiCl 2 .2H 2 O and 32.2 g CoCl 2 .6H 2 O in 200 cm 3 of water), respectively. The solutions left on the walls of the substrates were wiped off, and the coated substrates dried at 200° C. A 12-hour purging in a nitrogen atmosphere at 500° C. gave honeycomb catalysts 3S to 3X. COMPARATIVE EXAMPLE 3 Mother crystal 3M obtained in Example 6 was directly subjected to Cu ion exchange in the same manner as with the preparation of catalyst in Example 5 to obtain powder catalyst 3m'. Likewise a monolithic substrate was coated with it to yield honeycomb catalyst 3Y. EXPERIMENT 4 Honeycomb catalysts 3A to 3Y prepared in Examples 5 to 8 and in Comparative Example 3 were tested for the evaluation of their activities. The conditions for activity evaluation were as follows. Gas composition NO=400 ppm; CO=1000 ppm; C 2 H 4 =1000 ppm; C 3 H 6 =340 ppm; O 2 =8%; CO 2 =10%; H 2 O=10%; the remainder=N 2 ; (144 cells). The denitration rates of the catalysts in the initial state at reaction temperatures of 350° C. and 450° C. are given in Table 8. EXPERIMENT 5 As a durability test the catalysts were forced to deteriorate with the supply of a gaseous mixture consisting of 10% H 2 O and the balance N 2 gas at a GHSV of 30000 hr -1 for 24 hours. The forcibly deteriorated honeycomb catalysts 3A to 3Y were evaluated for their activities under the same conditions as used in Experiment 4. The results are also shown in Table 8. As Table 8 indicates, honeycomb catalysts 3A to 3X prepared using composite crystalline silicates had high denitration activities after the forced deterioration as well as in the initial state, proving that they were durable. The table also shows that the ordinary silicate catalyst (honeycomb catalyst 3Y) lost much of its activity after the forced deterioration, revealing that it was less durable. TABLE 7__________________________________________________________________________ Powder catalyst Qty of activeHoneycomb substance supported Composite crystalline silicatecatalyst No. No. (mmol/g) No. Composition*__________________________________________________________________________3A 3a Cu(0.45) 3A S.L/0.5Na.sub.2 O.0.5H.sub.2 O(0.2Fe.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3B 3b Cu(0.40) 3B S.L/0.5Na.sub.2 O.0.5H.sub.2 O(0.2Co.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3C 3c Cu(0.35) 3C S.L/0.4Na.sub.2 O.0.5H.sub.2 O(0.2Ru.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3D 3d Cu(0.40) 3D S.L/0.5Na.sub.2 O.0.4H.sub.2 O(0.2Rh.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3E 3e Cu(0.45) 3E S.L/0.5Na.sub.2 O.0.5H.sub.2 O(0.2La.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3F 3f Cu(0.40) 3F S.L/0.6Na.sub.2 O.0.4H.sub.2 O(0.2Ce.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3G 3g Cu(0.45) 3G S.L/0.5Na.sub.2 O.0.6H.sub.2 O(0.2Ti.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3H 3h Cu(0.35) 3H S.L/0.4Na.sub.2 O.0.6H.sub.2 O(0.2V.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3I 3i Cu(0.40) 3I S.L/0.5Na.sub.2 O.0.6H.sub.2 O(0.2Cr.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3J 3j Cu(0.45) 3J S.L/0.6Na.sub.2 O.0.4H.sub.2 O(0.2Sb.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3K 3k Cu(0.40) 3K S.L/0.6Na.sub.2 O.0.5H.sub.2 O(0.2Ga.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3L 3l Cu(0.50) 3L S.L/0.5Na.sub.2 O.0.5H.sub.2 O(0.2Nb.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3M 3m Cu(0.40) 3M S.L/0.4Na.sub.2 O.0.4H.sub.2 O.0.8Al.sub.2 O.sub.33N 3n Cu(0.40) 3A S.L/0.5Na.sub.2 O.0.4H.sub.2 O(0.2Fe.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3O 3o Co(0.35) 3A "3P 3p Ni(0.30) 3A "3Q 3q Fe(0.30) 3A "3R 3r Ag(0.70) 3A "3S -- CU(0.80) 3A(H type) S.L/H.sub.2 O.(0.2Fe.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3)3T -- Cu(0.80) 3A(H type) "3U -- Co(0.80) 3A(H type) "3V -- Ni(0.40) 3A(H type) "3W -- Cu(0.40) 3A (type) " Co(0.40)3X -- Ni(0.40) 3A (type) " Co(0.40)3Y m' Cu(0.40) 0.4Na.sub.2 O.0.8Al.sub.2 O.sub.3 (without__________________________________________________________________________ S.L) *In the composition, the symbol S.L stands for silicalite, and 25SiO.sub. is omitted because it is common to all the compositions. TABLE 8______________________________________Honey- Powder catalyst Activitycomb Qty of active Initial after forcedcata- substance activity deteriorationlyst supported (ηNOx %) (ηNOx %)No. No. (mmol/g) 350° C. 450° C. 350° C. 450° C.______________________________________3A 3a Cu(0.45) 41 40 38 363B 3b Cu(0.40) 39 38 37 353C 3c Cu(0.35) 40 41 37 363D 3d Cu(0.40) 38 40 38 353E 3e Cu(0.45) 39 41 39 383F 3f Cu(0.40) 37 40 35 353G 3g Cu(0.45) 38 41 36 353H 3h Cu(0.35) 37 38 36 353I 3i Cu(0.40) 38 36 35 343J 3j Cu(0.45) 37 40 36 333K 3k Cu(0.40) 38 39 37 343L 3l Cu(0.50) 38 41 36 373M 3m Cu(0.40) 38 40 39 353N 3n Cu(0.40) 38 36 34 333O 3o Co(0.35) 38 40 36 353P 3p Ni(0.30) 36 40 38 363Q 3q Fe(0.30) 35 40 36 343R 3r Ag(0.70) 36 38 35 333S -- Cu(0.80) 35 36 34 333T -- Cu(0.80) 36 35 33 323U -- Co(0.80) 36 38 32 333V -- Ni(0.40) 36 38 31 333W -- Cu(0.40) 35 36 31 31 Co(0.40)3X -- Ni(0.40) 35 37 35 32 Co(0.40)3Y m' Cu(0.40) 40 41 10 13______________________________________ With regard to the catalytic activities for the removal of CO and hydrocarbons, honeycomb catalysts 3A to 3X according to the third aspect of the invention underwent little changes in activity from the initial stage till after the forced deterioration. They showed 100% removal rates at both 350° C. and 450° C. Comparative honeycomb catalyst 3Y also had a CO and hydrocarbon purification activity of 100% initially at both 350° C. and 450° C. After the forced deterioration, however, the CO removal rates of comparative honeycomb catalyst 3Y at 350° C. and 450° C. declined to 35% and 75%, respectively, and the hydrocarbon removal rates at those temperatures also dropped to 45% and 90%. The fourth aspect of the present invention will now be described in detail by way of Examples 9 to 12 and Comparative Example 4. EXAMPLE 9 Synthesis of mother crystal 4A A solution of 5616 g water glass #1 (contg. 30% SiO 2 ) in 5429 g of water is prepared and referred to as solution 4A. Meanwhile 718.9 g of aluminum sulfate, 110 g of ferric chloride, 47.2 g of calcium acetate, 262 g of sodium chloride, and 2020 g of concentrated hydrochloric acid are dissolved in 4175 g of water, and the solution is designated solution 4B. Solutions 4A and 4B are fed at a predetermined ratio, and the mixture is caused to precipitate. Thorough agitation yields a slurry of pH 8.0. This slurry is charged into a 20-liter autoclave and, with the addition of 500 g of tetrapropylammonium bromide, the mixture is subjected to hydrothermal synthesis at 160° C. for 72 hours. The synthesis is followed by water rinsing, drying, and baking at 500° C. for 3 hours to obtain crystalline silicate 4A. This crystalline silicate is represented, in terms of the molar ratio of the oxides (excluding crystal water), by the compositional formula: 0.5Na.sub.2 O.0.5H.sub.2 O.[0.8Al.sub.2 O.sub.3.0.2Fe.sub.2 O.sub.3.0.25CaO].25SiO.sub.2 and has a crystal structure according to an X-ray diffraction analysis as shown in Table 1 above. Synthesis of composite crystalline silicate 4A One thousand grams of the mother crystal 4A (crystalline silicate 4A) in a finely powdered state is added to 2160 g of water. With the further addition of 4590 g of colloidal silica (contg. 20% SiO 2 ), the mixture is thoroughly stirred, and the resulting solution is designated as solution 4a. In the meantime 105.8 g of sodium hydroxide is dissolved in 2008 g of water to prepare solution 4b. While solution 4a is kept under agitation, solution 4b is slowly added drop-wise into solution 4a to form a precipitate and obtain a slurry. This slurry is placed in an autoclave and a solution of 568 g of tetrapropylammonium bromide in 2106 g of water is added. Inside the autoclave hydrothermal synthesis is carried out at 160° C. for 72 hours (with stirring at 200 rpm). After the stirring, the synthesis product is rinsed, dried, and baked at 500° C. for 3 hours to yield laminar composite crystalline silicate 4A. Preparation of catalysts Composite crystalline silicate 4A was subjected to copper ion exchange by immersion in a 0.04M aqueous copper acetate solution at 30° C. with stirring. After 24-hour stirring, it was rinsed, and this cycle was repeated to conduct the copper ion exchange with the aqueous solution Three times. Final rinsing and drying gave powder catalyst 4a. To 100 parts of powder catalyst 4a added as binders were 3 parts of alumina sol, 55 parts silica sol (contg. 20% SiO 2 ), and 200 parts water. The mixture upon thorough stirring afforded a slurry for wash coating. A monolithic substrate (with a 400-cell lattice pattern) for cordierite was dipped in the slurry and taken out, excess slurry was blown away, and then dried at 200° C. The coating so supported weighed 200 g per liter of the substrate, and this coated matter is designated as honeycomb catalyst 4A. EXAMPLE 10 Mother crystals 4B to 4L were prepared by repeating the procedure for the synthesis of mother crystal 4A in Example 9 with the exception that the ferric chloride was replaced by the chlorides of cobalt, ruthenium, rhodium, lanthanum, cerium, titanium, vanadium, chromium, antimony, gallium, and niobium, respectively, each in the same molar amount as Fe 2 O 3 in terms of equivalency as oxide. The compositions of these mother crystals are represented, as the molar ratio of the oxides (in the dehydrated state), by the formula: 0.5Na.sub.2 O.0.5H.sub.2 O.[0.2M.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO].25SiO.sub.2 wherein M is Co, Ru, Rh, La, Ce, Ti, V, Cr, Sb, Ga, or Nb, constituting mother crystals 4B to 4L, respectively. In the same manner as with mother crystal 4A but without the addition of the ferric chloride and calcium acetate, mother crystal 4M was obtained. These mother crystals 4B to 4M were finely powdered and used in place of mother crystal 4A in the synthesis of the crystalline silicate in Example 9. Repeated runs of hydrothermal synthesis using the autoclave gave composite crystalline silicates 4B to 4M. Using these crystalline silicates 4B to 4M, the procedure of Example 9 for the preparation of a catalyst was repeated, and powder catalysts 4b to 4m were obtained. These powder catalysts were used to coat monolithic substrates of cordierite, in the same way as in the preparation of catalyst in Example 9, and honeycomb catalysts 4B to 4M were obtained. EXAMPLE 11 In the synthesis of mother crystal 4A in Example 9 calcium acetate was replaced by magnesium acetate, strontium acetate, or barium acetate, each in the same molar amount as CaO in terms of equivalency as oxide, and otherwise the same procedure with the mother crystal 4A was repeated to prepare mother crystals 4N to 4P. The compositions of these mother crystals, in terms of the molar ratio of the oxides (in a dehydrated state) were represented by: 0.5Na.sub.2 O.0.5H.sub.2 O.(0.2Fe.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25MeO).25SiO.sub.2 wherein Me is Mg, Sr, or Ba. These mother crystals were finely ground and were subjected to hydrothermal synthesis using the autoclave in the same manner as with the synthesis of the crystalline silicates in Example 9 to obtain crystalline silicates 4N to 4P. From these silicates 4N to 4P, powder catalysts 4n to 4p and then honeycomb catalysts 4N to 4P were obtained by following the procedure of Example 9. EXAMPLE 12 Divided portions of composite crystalline silicate 4A obtained in Example 9 were immersed with agitation in 0.04M aqueous solutions of cupric chloride, cobalt chloride, nickel chloride, ferric chloride, and silver nitrate at 60° C. for ion exchange with the respective metals. Then, in the same way as described in Example 9, powder catalysts 4q to 4u were prepared. These powder catalysts were supported by monolithic substrates in the manner described in Example 9, and honeycomb catalysts 4Q to 4U were obtained. EXAMPLE 13 The crystalline silicate 4A prepared in Example 9 was immersed in a 4N aqueous NH 4 Cl solution at 80° C. and was stirred for 24 hours for NH 4 ion exchange. Following the ion exchange, the product was rinsed, dried at 100° C. for 24 hours, and baked at 500° C. for 3 hours to give H type crystalline silicate 4A'. With the addition of binder, this silicate 4A' was applied to a cordierite type monolithic substrate as a coating. Divided portions of the coated monolithic substrate were separately immersed for impregnation over a one-hour period in a solution of cuprous chloride in hydrochloric acid (26.8 g in 200 cm 3 of HCl), aqueous cupric chloride solution (46.1 g in 200 cm 3 of water), aqueous cobalt chloride solution (64.4 g in 200 cm 3 of water), aqueous nickel chloride (64.4 g in 200 cm 3 of water), aqueous solution mixture of cupric chloride and cobalt chloride (23.1 g CuCl 2 .2H 2 O and 32.2 g CoCl 2 .6H 2 O in 200 cm 3 of water), and aqueous solution mixture of nickel chloride and cobalt chloride (32.2 g NiCl 2 .2H 2 O and 32.2g CoCl 2 .6H 2 O in 200 cm 3 of water), respectively. The solutions left on the walls of the substrates were wiped off, and the coated substrates dried at 200° C. A 12-hour purging in a nitrogen atmosphere at 500° C. gave honeycomb catalysts 4V to 4α. COMPARATIVE EXAMPLE 4 Mother crystal 4M obtained in Example 10 was directly subjected to Cu ion exchange in the same manner as with the preparation of catalyst in Example 9 to obtain powder catalyst 4m'. Likewise a monolithic substrate was coated with it to yield honeycomb catalyst 4β. EXPERIMENT 6 Honeycomb catalysts 4A to 4β prepared in Examples 9 to 13 and in Comparative Example 4 were tested for the evaluation of their activities. The conditions for activity evaluation were as follows. Gas composition NO=400 ppm; CO=1000 ppm; C 2 H 4 =1000 ppm; C 3 H 6 =340 ppm; O 2 =8%; CO 2 =10%; H 2 O=10%; the remainder=N 2 ; GHSV=30000 hr -1 ; catalyst shape=15 mm×15 mm×60 mm (144 cells). The denitration rates of the catalysts in the initial state at reaction temperatures of 350° C. and 450° C. are given in Table 10. EXPERIMENT 7 As a durability test the catalysts were forced to deteriorate with the supply of a gaseous mixture consisting of 10% H 2 O and the balance N 2 gas at a GHSV of 30000 hr -1 for 24 hours. The forcibly deteriorated honeycomb catalysts 4A to 4β were evaluated for their activities under the same conditions as used in Experiment 6. The results are also shown in Table 10. As Table 10 indicates, the honeycomb catalysts 4A to 4α prepared using composite crystalline silicates according to the fourth aspect of the invention had high denitration activities after the forced deterioration as well as in the initial state, proving that they were durable. The table also shows that the ordinary silicate catalyst (honeycomb catalyst 4β) lost much of its activity after the forced deterioration, revealing that it was less durable. TABLE 9__________________________________________________________________________ Powder catalyst Qty of activeHoneycomb substance supported Composite crystalline silicatecatalyst No. No. (mmol/g) No. Composition*__________________________________________________________________________A a Cu(0.45) A S.L/0.5Na.sub.2 O.0.5H.sub.2 O(0.2Fe.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)B b Cu(0.40) B S.L/0.5Na.sub.2 O.0.5H.sub.2 O(0.2Co.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)C c Cu(0.35) C S.L/0.4Na.sub.2 O.0.5H.sub.2 O(0.2Ru.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)D d Cu(0.40) D S.L/0.5Na.sub.2 O.0.4H.sub.2 O(0.2Rh.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)E e Cu(0.45) E S.L/0.5Na.sub.2 O.0.5H.sub.2 O(0.2La.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)F f Cu(0.40) F S.L/0.6Na.sub.2 O.0.4H.sub.2 O(0.2Ce.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)G g Cu(0.45) G S.L/0.5Na.sub.2 O.0.6H.sub.2 O(0.2Ti.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)H h Cu(0.35) H S.L/0.4Na.sub.2 O.0.6H.sub.2 O(0.2V.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)I i Cu(0.40) I S.L/0.5Na.sub.2 O.0.6H.sub.2 O(0.2Cr.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)J j Cu(0.45) J S.L/0.6Na.sub.2 O.0.4H.sub.2 O(0.2Sb.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)K k Cu(0.40) K S.L/0.6Na.sub.2 O.0.5H.sub.2 O(0.2Ga.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)L l Cu(0.50) L S.L/0.5Na.sub.2 O.0.5H.sub.2 O(0.2Nb.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)M m Cu(0.40) M S.L/0.4Na.sub.2 O.0.4H.sub.2 O.0.8Al.sub.2 O.sub.3N n Cu(0.45) N S.L/0.5Na.sub.2 O.0.5H.sub.2 O(0.2Fe.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25MgO)O o Cu(0.45) O S.L/0.5Na.sub.2 O.0.5H.sub.2 O(0.2Fe.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25SrO)P p Cu(0.45) P S.L/0.5Na.sub.2 O.0.5H.sub.2 O(0.2Fe.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25BaO)Q q Cu(0.40) A S.L/0.5Na.sub.2 O.0.5H.sub.2 O(0.2Fe.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)R r Co(0.35) A "S s Ni(0.30) A "T t Fe(0.30) A "U u Ag(0.70) A "V Cu(0.80) A'(H type) S.L/H.sub.2 O.(0.2Fe.sub.2 O.sub.3.0.8Al.sub.2 O.sub.3.0.25CaO)W Cu(0.80) A'(H type) "X Co(0.80) A'(H type) "Y Ni(0.40) A'(H type) "Z Cu(0.40) A'(H type) " Co(0.40)α Ni(0.40) A'(H type) " Co(0.40)β m' Cu(0.40) 0.4Na.sub.2 O.0.8Al.sub.2 O.sub.3 (without__________________________________________________________________________ S.L) In the composition, the symbol S.L stands for silicalite, and 25SiO.sub.2 is omitted because it is common to all the compositions. TABLE 10______________________________________Honey- Powder catalyst Activitycomb Qty of active Initial after forcedcata- substance activity deteriorationlyst supported (ηNOx %) (ηNOx %)No. No. (mmol/g) 350° C. 450° C. 350° C. 450° C.______________________________________A a Cu(0.45) 40 40 39 36B b Cu(0.40) 39 39 37 34C c Cu(0.35) 41 41 38 36D d Cu(0.40) 38 38 38 34E e Cu(0.45) 38 41 37 38F f Cu(0.40) 37 40 35 36G g Cu(0.45) 38 42 35 35H h Cu(0.35) 38 38 36 34I i Cu(0.40) 38 35 35 34J j Cu(0.45) 37 40 35 32K k Cu(.040) 37 39 37 34L l Cu(0.50) 38 37 37 36M m Cu(0.40) 39 40 39 37N n Cu(0.45) 39 36 38 36O o Cu(0.45) 40 37 36 35P p Cu(0.45) 41 40 37 34Q q Cu(0.40) 39 36 35 33R r Cu(0.35) 39 40 36 36S s Ni(0.30) 36 39 37 36T t Fe(0.30) 36 40 37 36U u Ag(0.70) 36 39 35 33V -- Cu(0.80) 36 36 35 33W -- Cu(0.80) 36 38 33 34X -- Co(0.80) 35 38 33 33Y -- Ni(0.40) 36 39 31 32Z -- Cu(0.40) 36 36 33 31 Co(0.40)α -- Ni(0.40) 35 38 35 31 Co(0.40)β m' Cu(0.40) 39 42 6 12______________________________________
A catalyst for exhaust gas purification having a crystalline silicate including an oxide of an alkali metal and/or hydrogen ion, aluminum oxide, an oxide of an alkaline earth metal, Ca, Mg, Sn, or Ba, an X-ray diffraction pattern described in Table 1 in the specification, and containing at least one metal from the group consisting of the elements in Groups Ib and VIII of the periodic table, rare earth elements, titanium, vanadium, chromium, antimony, zinc, and manganese. With the use of a crystalline silicate containing alkaline earth elements together with other metals or with a composite structure of catalyst, the separation of aluminum or other metals from the crystal lattices (dealuminization or demetallization) can be controlled, and heat and steam resistance may be achieved.
8
This application claims the benefit under 35 U.S.C. §371 of International Application No. PCT/US2007/087044 filed Dec. 11, 2007 which claims benefit under 35 U.S.C. §119(e) of U.S. Ser. No. 60/871,302 filed Dec. 21, 2006. BACKGROUND OF THE INVENTION Plk1 belongs to a small family of protein kinases characterized by a phosphoserine/threonine binding domain known as the polo box domain. Plk1 plays a central role in the regulation of the cell cycle. Among other functions, Plk1 is thought to regulate initiation, progression, and exit from mitosis, the stage when cancer cells divide. Consequently, blocking Plk1 in cancer cells prevents their division or mitosis. Potent anticancer agents have been identified that interfere with mitosis such as the vinca alkaloids (NAVELBINE®), taxoids (TAXOTERE®) and topoisomerase II inhibitors (ADRIAMYCIN®). VELCADE® is an antineoplastic agent that inhibits the 26S proteosome. However, these drugs cause considerable side effects upon normal, non-dividing cells. Plk inhibitors specifically target dividing cells and may be able to avoid the undesirable toxicities. Inhibitors of Plk1 are known in the art. See for example, WO 06/066172. Additionally, WO 06/021548 discloses certain dihydropteridinone analogs (e.g., BI-2536) as inhibitors of Plk1. Currently, BI-2536 is in phase II clinical trials but has high clearance (CL >1000 mL/min) and is dose limited by myelosupression in man. There is still a need for further compounds that inhibit Plk1 which possess improved potency or pharmacokinetic properties. It would also be advantageous to have a Plk1 inhibitor that could be dosed orally. The present invention provides novel imidazolidinonyl aminopyrimidine compounds believed to have clinical use for treatment of cancer through inhibiting Plk1. Certain of these compounds are believed to have improved potency over compounds disclosed in WO 06/066172. Additionally, certain of these compounds are believed to have improved pharmacokinetic properties over BI-2536. Further, due to the oral bioavailability of the compounds of the present invention that were tested, it is believed that certain of these compounds could be dosed orally. BRIEF SUMMARY OF THE INVENTION The present invention provides compounds of Formula I: wherein: R 1 hydrogen, hydroxy, hydroxymethyl, halo, methyl, fluoromethyl, C 1 -C 2 alkoxy, amino, or methylamino; R 2 is hydrogen, halo, or cyano; R 3 is hydrogen or halo; provided that at least one of R 1 , R 2 , and R 3 is hydrogen; and R 4 is hydrogen, halo, or methyl; or a pharmaceutically acceptable salt thereof. The present invention provides a method of treating cancer selected from the group consisting of non-small cell lung, oropharyngeal, oesophageal, gastric, melanoma, epidermoid carcinoma of the skin, breast, ovarian, endometrial, colorectal, neuroglioma, glioblastoma, thyroid carcinoma, cervical, pancreatic, prostate, hepatoblastoma and non-Hodgkin lymphoma cancers in a mammal comprising administering to a mammal in need of such treatment an effective amount of a compound of Formula I or a pharmaceutically acceptable salt thereof. The present invention also provides a pharmaceutical composition comprising a compound of Formula I or a pharmaceutically acceptable salt thereof, in combination with a pharmaceutically acceptable excipient, carrier, or diluent. This invention also provides a compound of Formula I or a pharmaceutically acceptable salt thereof for use in the preparation of a medicament. Additionally, this invention provides a compound of Formula I or a pharmaceutically acceptable salt thereof for use in the preparation of a medicament for the treatment of cancer in mammals, selected from the group consisting of non-small cell lung, oropharyngeal, oesophageal, gastric, melanoma, epidermoid carcinoma of the skin, breast, ovarian, endometrial, colorectal, neuroglioma, glioblastoma, thyroid carcinoma, cervical, pancreatic, prostate, hepatoblastoma and non-Hodgkin lymphoma cancers. Furthermore, this invention provides a pharmaceutical composition adapted for the treatment of cancer selected from the group consisting of non-small cell lung, oropharyngeal, oesophageal, gastric, melanoma, epidermoid carcinoma of the skin, breast, ovarian, endometrial, colorectal, neuroglioma, glioblastoma, thyroid carcinoma, cervical, pancreatic, prostate, hepatoblastoma and non-Hodgkin lymphoma cancers comprising a compound of Formula I or a pharmaceutically acceptable salt thereof in combination with one or more pharmaceutically acceptable excipients, carriers, or diluents. The present invention also provides compounds of the Formula: wherein: R 1 hydrogen, hydroxy, halo, methyl, C 1 -C 2 alkoxy, amino, or methylamino; R 2 is hydrogen, halo, or cyano; R 3 is hydrogen or halo; R 4 is hydrogen, halo, or methyl; provided that at least two of R 1 , R 2 , R 3 , and R 4 are hydrogen; R 5 is hydrogen, halo, or methyl; or a pharmaceutically acceptable salt thereof. DETAILED DESCRIPTION OF THE INVENTION The general chemical terms used in the formulae above have their usual meanings. For example, the term “(C 1 -C 2 )alkoxy” means methoxy and ethoxy. The term “halo” means fluoro, chloro, bromo, and iodo. It will be understood by the skilled reader that most or all of the compounds of the present invention are capable of forming salts. The compounds of the present invention are amines, and accordingly react with any of a number of inorganic and organic acids to form pharmaceutically acceptable acid addition salts. Such pharmaceutically acceptable acid addition salts and common methodology for preparing them are well known in the art. See, e.g., P. Stahl, et al., HANDBOOK OF PHARMACEUTICAL SALTS: PROPERTIES, SELECTION AND USE, (VCHA/Wiley-VCH, 2002); S. M. Berge, et al., “Pharmaceutical Salts,” Journal of Pharmaceutical Sciences , Vol 66, No. 1, January 1977. Preferred are compounds of Formula I wherein: a) R 1 is hydrogen or methyl; b) R 2 is hydrogen or halo; c) R 3 is hydrogen or halo; d) R 4 is halo; e) R 4 is methyl; f) R 4 is hydrogen; g) R 1 is hydrogen, R 2 is chloro, R 3 is hydrogen, and R 4 is hydrogen; h) R 1 is methyl, R 2 is hydrogen, R 3 is fluoro, and R 4 is fluoro; and i) R 1 is methyl, R 2 is hydrogen, R 3 is fluoro, and R 4 is methyl; Schemes The skilled artisan will appreciate that not all of the substituents in the compounds of the present invention will tolerate certain reaction conditions employed to synthesize the compounds. These moieties may be introduced at a convenient point in the synthesis, or may be protected and then deprotected as necessary or desired. The skilled artisan will appreciate that the protecting groups may be removed at any convenient point in the synthesis of the compounds of the present invention. Methods for introducing and removing nitrogen and oxygen protecting groups are well known in the art; see, for example, Greene and Wuts, Protective Groups in Organic Synthesis, 3 rd Ed., John Wiley and Sons, New York, Chapter 7 (1999). Furthermore, the skilled artisan will appreciate that in many circumstances, the order in which moieties are introduced is not critical. The particular order of steps required to produce the compounds of the present invention can be dependent upon the particular compound being synthesized, the starting compound, and the relative lability of the substituted moieties. Compounds of the present invention can be prepared by carrying out at least two variants discussed below. In the schemes below all substituents, unless otherwise indicated, are as previously defined and suitable reagents are well known and appreciated in the art. In Scheme 2, Y is halo and Z is boronic acid. A compound of Formula (1) is reacted with 2-(amino-ethyl)-1,3-dihydro-imidazol-one (2) to give a compound of Formula (5) via a nucleophilic displacement reaction. Such reactions are carried out in a suitable solvent, such as n-butanol, dioxane, N-methylpyrrolidin-2-one (NMP), and the like. Generally, the reactions are carried out at temperatures of from about 120° C. to 150° C. using an oil bath or a microwave reactor. Typical stoichiometry for this reaction is based on the compound of Formula (3) and about 2 equivalents of 2-(amino-ethyl)-1,3-dihydro-imidazol-one are used Amine bases, such as triethyl amine, diisopropylethyl amine, and the like, can be used. A compound of Formula (3) is reacted with a compound of Formula (4) in a Suzuki reaction using a suitable palladium catalyst, such as tetrakis(triphenylphosphine)palladium(0), [1,1′-bis(diphenylphosphino)ferrocene]dichloropalladium(II), and the like in the presence of a base, such as sodium carbonate, potassium carbonate, and the like. Such reactions are carried out in a suitable solvent, such as THF, dioxane, water, and the like. Generally, the reactions are carried out at temperatures of from about 100° C. to 150° C. using an oil bath or a microwave reactor. In an optional step, a pharmaceutically acceptable salt of a compound of the present invention is formed. The formation of such salts is well known and appreciated in the art. As will be readily appreciated compounds of Formulas (1) and (3) can be readily prepared by methods similar to those described herein by procedures that are well-known and established in the art. For example, compounds of Formula (1) are prepared by coupling an optionally substituted pyridinyl compound with an optionally substituted benzothiophenyl compound by Suzuki coupling methods, as described above. The resulting Suzuki adduct is boronylated by methods well known in the art and further coupled to an optionally substituted pyrimidine halide via Suzuki coupling methods, as described above. Compounds of Formula (3) are prepared by boronylation of an optionally substituted benzothiophenyl compound by methods well known in the art followed by addition of 2-(amino-ethyl)-1,3-dihydro-imidazol-one (2) to the resulting boronic acid/ester via nucleophilic aromatic substitution. Also, it is recognized that the steps required to prepare a compound of Formula (1) or (3) can be carried out in any order including reaction of a partial compound of Formula (1) or (3) with a compound of Formula (2) and/or Formula (4), such that the later carried out carbon-carbon bond formation, coupling reaction, etc, provide a compound of the present invention. The present invention is further illustrated by the following examples and preparations. These examples and preparations are illustrative only and are not intended to limit the invention in any way. The terms used in the examples and preparations have their normal meanings unless otherwise designated. The example compounds below were named using ChemDraw®, Version 10. Preparation 1 2-Benzo[b]thiophen-7-yl-4,4,5,5-tetramethyl-[1,3,2]dioxaborolane Combine 7-bromo-benzo[b]thiophene (426 mg, 2 mmol), bis(pinacolato)diboron (756 mg, 3 mmol), [1,1′-bis(diphenylphosphino)ferrocene]dichloropalladium(II), complex with dichloromethane (1:1) (81 mg, 0.1 mmol), potassium acetate (294 mg, 3 mmol) in dimethyl sulfoxide (DMSO) (10 mL) in a flask. Bubble nitrogen through the mixture for 5 min. Seal the flask and heat in an oil bath at 100° C. for 4 hours. Dilute the mixture with chloroform/isopropanol (3/1). Wash the solution with saturated aqueous sodium chloride. Dry the solution over sodium sulfate. Concentrate the solution in vacuo to a dark residue. Purify by column chromatography (hexane to 20% ethyl acetate in hexane) to afford the title compound (342 mg, 66%) as a colorless solid. MS (ES) m/z 261 [M+1] + . Preparation 2 Benzo[b]thiophene-7-boronic acid Combine 7-bromobenzo[b]thiophene (300 g, 1.41 mmol) and triisopropylborate (403.6 g, 2.15 mmol) in anhydrous tetrahydrofuran (THF) (4000 mL) in a 12 L Morton flask fitted with a mechanical stirrer and cool under nitrogen in a dry-ice/acetone bath to −70° C. Add n-butyl lithium (1.6 M in hexane, 714 g, 1.68 mmol) dropwise at such a rate as to keep the internal temperature less than −67.5° C. After the addition is complete, allow the reaction mixture to stir at this temperature for 1 hour. Remove the cooling bath and slowly add 4 L of water. Add concentrated HCl (75 mL) until the pH of the solution is about pH=2. Allow the slurry to stir for 1 hour. Add sufficient 5 N aqueous NaOH to adjust the pH of the mixture to about pH=12. Separate the layers and save the aqueous layer. Dilute organic layer with 4 L of methyl-tert-butyl ether and extract with 1 L of 5 N aqueous NaOH. Separate the layers. Combine the aqueous layer with the previous aqueous extract. Wash the aqueous layer with additional methyl-tert-butyl ether (4 L). Separate the layers and transfer the aqueous layers to a 12 L 3-neck round bottom flask fitted with a mechanical stirrer. Cool the solution to +5° C. with an ice-water bath. Add concentrated HCl slowly until the pH of the solution is about pH=2. Stir the mixture for 30 min and filter off the resulting solid. Rinse the solid on the funnel twice with 2 L of water and allow to air-dry for 30 min. Place the solid in a vacuum oven at 50° C. and dry under vacuum overnight. Remove the yellow color by slurrying the dried solid with 2 L of n-heptane for 30 min. Again filter off the solid, air-dry for 30 min, and vacuum dry at 40° C. overnight to afford the title compound (188.8 g, 75%) as a white solid. 1 H NMR (400 MHz, CD 3 OD) δ 7.86 (d, J=8 Hz, 1H), 7.49-7.57 (m, 2H), 7.30-7.39 (m, 2H). Preparation 3 (6-Fluoro-pyridin-3-yl)-carbamic acid tert-butyl ester Equip a 100 mL 3 neck round bottom flask with: a magnetic stirrer, a thermocouple controlled heating mantle, a condenser, and a nitrogen atmosphere. Charge 5-amino-2-fluoro-pyridine (5 g, 44.6 mmol), THF (50 mL), 4-dimethylaminopyridine (549 mg, 4.5 mmol, 10 mol %), and di-tert-butyl-dicarbonate (10.7 g, 49 mmol). Heat the mixture to 50° C. for 4 hours. Cool and concentrate in vacuo. Dissolve residue into dichloromethane/water and filter. Transfer filtrate to a separatory funnel and separate the dichloromethane layer. Dry the dichloromethane over sodium sulfate, filter and concentrate in vacuo. Chromatograph on silica eluting with an isocratic mixture of 10% isopropanol/90% dichloromethane to give the title compound (1.64 g, 17%) as a tan, clear oil that solidifies upon vacuum drying. MS (EI) m/z 261 M. Preparation 4 (2-Fluoro-pyridin-3-yl)-carbamic acid tert-butyl ester Prepare the title compound essentially according to the preparation of (6-fluoro-pyridin-3-yl)-carbamic acid tert-butyl ester using the appropriate starting material. GCMS (EI) m/z 212 M. Preparation 5 N-(4-Iodo-pyridin-3-yl)-2,2-dimethyl-propionamide Equip a 250 mL 3-neck round bottom flask with: a magnetic stirrer, a thermocouple, a dry ice/acetone bath, a nitrogen atmosphere, and an addition funnel. Charge 2,2-dimethyl-N-pyridin-3-yl-propionamide (3.0 g, 16.8 mmol), diethyl ether (67 mL), tetramethylene diamine (4.68 g, 6.08 mL, 40.3 mmol). Cool the reaction to −78° C. Add slowly via glass syringe n-butyllithium (2.5 M solution in hexane, 16.2 mL, 40.3 mmol) over 10 min. Allow the reaction to warm to −13° C. over 2 hours. Cool the reaction to −78° C. Add an iodine solution (8.5 g, 33.6 mmol in 20 mL THF) to the reaction via the addition funnel and mix 2.5 hours at −68° C. Quench the reaction by the addition of saturated aqueous NH 4 Cl solution (40 mL). Extract with ethyl acetate (100 mL) and discard the aqueous phase. Wash the organic layer with a saturated aqueous sodium thiosulfate solution (100 mL) and saturated aqueous sodium chloride. Dry the organic phase over sodium sulfate and filter. Concentrate in vacuo to give brown oil. Chromatograph on silica (80 g) eluting with a gradient of 100% dichloromethane to 70% ethyl acetate/30% dichloromethane to afford the title compound (1.19 g, 23%). MS (ES) m/z 305 [M+1] + Prepare the following compounds essentially according to the preparation of N-(4-iodo-pyridin-3-yl)-2,2-dimethyl-propionamide using the appropriate starting material. Physical Prep Compound Name Data 6 (6-Fluoro-4-iodo-pyridin-3-yl)-carbamic acid MS (ES) tert-butyl ester m/z 339 [M + 1] + 7 (2-Fluoro-4-iodo-pyridin-3-yl)-carbamic acid GC-MS (EI) tert-butyl ester m/z 338 M + Preparation 8 3-Methoxymethoxy-pyridine Dissolve 3-hydroxypyridine (7 g, 74 mmol) in THF (20.6 mL) and dimethylformamide (34.4 mL) and cool to −15° C. Add potassium tert-butoxide (8.3 g, 74 mmol) and stir at −15° C. for 30 min. Treat the mixture with chloromethylmethyl ether (5.81 mL, 77 mmol) dropwise over 40 min. After the addition is complete, stir the mixture at −15° C. for an additional hour. Remove the ice bath and allow the mixture to warm slowly to 15° C. Pour the mixture into saturated aqueous sodium chloride and stir vigorously for 10 min. Extract the resulting solution with three portions of ethyl acetate. Combine the organic extracts and wash with saturated aqueous sodium chloride, dry over sodium sulfate, filter, and concentrate in vacuo. Use the resulting product without further purification. 1 H NMR (400 MHz, CDCl 3 ) δ 8.42 (d, J=3 Hz, 1H), 8.28 (d, J=5 Hz, 1H), 7.37-7.42 (m, 1H), 7.21-7.27 (m, 1H), 5.20 (s, 2H), 3.49 (s, 3H). Preparation 9 2-Chloro-5-methoxymethoxy-pyridine Suspend sodium hydride (3.7 g, 93 mmol) in DMF (50 mL) and add a solution of 2-chloro-5-hydroxypyridine (10 g, 77 mmol) in DMF (20 mL) dropwise over 45 min. Stir the resulting solution at room temperature for 1.5 hours. Add chloromethylmethyl ether (6.6 mL, 86 mmol) dropwise over 45 min. Stir the resulting mixture at room temperature for 12 hours. Dilute the mixture with ethyl acetate, water, and saturated aqueous sodium chloride. Isolate the organic solution and wash with three portions of water, one portion of saturated aqueous sodium chloride, dry over sodium sulfate, filter, and concentrate in vacuo. Purify the crude product by column chromatography on 330 g of silica gel eluting with a gradient from hexane to 30% ethyl acetate in hexane over 20 min and then hold at 30% ethyl acetate in hexane for 30 min to give the title compound (10.8 g, 81%) as a clear oil. MS (ES) m/z 174.0 [M+1] + . Prepare the following intermediate with methods similar to those used for 2-chloro-5-methoxymethoxy-pyridine. Prep Compound Name NMR 10 2-Fluoro-5-methoxymethoxy- 1 H NMR (400 MHz, CDCl 3 ) δ pyridine 3.48 (s, 3H), 5.15 (s, 2H), 6.85 (dd, J = 3.6 Hz, J = 8.8 Hz, 1H), 7.47 (m, 1H), 7.96 (m, 1H) Preparation 11 2-Chloro-4-iodo-5-methoxymethoxy-pyridine Add tert-buty lithium (1.7 M in pentane, 72 mL, 123 mmol) to a solution of 2-chloro-5-methoxymethoxy-pyridine (10.8 g, 62 mmol) in THF (300 mL) at −70° C. dropwise over 10 min. Stir the resulting solution at −70° C. for 30 min. Add a solution of iodine (23 g, 92 mmol) in THF (150 mL) dropwise over 30 min. Stir the resulting solution at −70° C. for 1 hour. Remove the ice bath and allow the reaction to warm to room temperature. Dilute the mixture with ethyl acetate and water and isolate the phases. Extract the aqueous phase with two portions of ethyl acetate. Combine the organic extracts and wash with two portions of aqueous sodium thiosulfate, one portion of water, one portion of saturated aqueous sodium chloride, dry over sodium sulfate, filter and concentrate in vacuo. Triturate the resulting solid with hexane. Collect the solid by vacuum filtration and wash the solid with hexane. Dry the solid under vacuum to give the title compound (10.8 g, 58%) as a brown solid. 1 H NMR (400 MHz, DMSO-d 6 ) δ 8.08 (s, 1H), 7.98 (s, 1H), 5.43 (s, 2H), 3.40 (s, 3H). Prepare the following intermediate using essentially the procedure for 2-chloro-4-iodo-5-methoxymethoxy-pyridine. Prep Compound Name NMR 12 2-Fluoro-4-iodo-5- 1 H NMR (400 MHz, CDCl 3 ) δ methoxymethoxy-pyridine 3.53 (s, 3H), 5.23 (s, 2H), 7.39 (d, J = 4.0 Hz, 1H), 7.96 (d, J = 1.6 Hz, 1H) Preparation 13 6-Chloro-4-iodo-pyridin-3-ol Treat a solution of 2-chloro-4-iodo-5-methoxymethoxy-pyridine (8.1 g, 27 mmol) in THF (40 mL) with 3 N HCl (61 mL). Heat the resulting mixture to 60° C. for 3 hours. Cool the mixture to room temperature and adjust the pH to 7 by the slow addition of saturated aqueous sodium bicarbonate solution. Extract the mixture with three portions of ethyl acetate. Combine the organic extracts and dry over sodium sulfate, filter, and concentrate in vacuo to give the title compound (6.8 g, 98%) as a brown solid used without further purification. 1 H NMR (400 MHz, DMSO-d 6 ) δ 11.04 (s, 1H), 7.81-7.87 (m, 2H). Prepare the following intermediate using essentially the procedure for 6-chloro-4-iodo-pyridin-3-ol. MS (ES) Prep Compound Name [M + 1] + 14 6-Fluoro-4-iodo-pyridin-3-ol 240 Preparation 15 2-Chloro-5-ethoxy-4-iodo-pyridine Treat a solution of 6-chloro-4-iodo-pyridin-3-ol (4.9 g, 19 mmol) and potassium carbonate (8.0 g, 58 mmol) in dimethylformamide (50 mL) with ethyl iodide (4.7 mL, 58 mmol). Heat at 60° C. for 3 hours. Cool the mixture to room temperature and filter. Dilute the mixture with ethyl acetate and wash with a 10% aqueous citric acid solution. Combine the aqueous solutions and extract with two additional portions of ethyl acetate. Combine the organic extracts and wash with three portions of water, one portion of saturated aqueous sodium chloride, dry over sodium sulfate, filter, and concentrate in vacuo to give the title compound (5.1 g, 93%) as a brown solid used without further purification. 1 H NMR (400 MHz, DMSO-d 6 ) δ 8.00 (s, 1H), 7.93 (s, 1H), 4.18 (q, J=7 Hz, 2H), 1.35 (t, J=7 Hz, 3H). Preparation 16 4-Benzo[b]thiophen-7-yl-2-chloro-pyridine In a flask, combine 7-bromo-benzo[b]thiophene (1.7 g, 12 mmol), 2-chloro-4-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-pyridine (1.6 g, 7 mmol), [1,1′-bis(diphenylphosphino)ferrocene]dichloropalladium(II), complex with dichloromethane (1:1) (285 mg, 0.3 mmol), 2-(di-tert-butylphosphino)biphenyl (63 mg, 0.2 mmol), sodium carbonate (2 M, 8 mL, 16 mmol) and THF (20 mL). Heat the mixture at 100° C. for 3 hours. Dilute the mixture with chloroform/isopropanol (3/1). Wash the solution with saturated aqueous sodium chloride. Dry over sodium sulfate. Concentrate the solution in vacuo to a dark residue. Purify by column chromatography (dichloromethane to 20% THF in dichloromethane) to afford the title compound (1.14 g, 66%) as a yellow solid. MS (ES) m/z 246 [M+1] + . Prepare the following compounds by methods similar to those used for 4-benzo[b]thiophen-7-yl-2-chloro-pyridine using DMSO. MS (ES) Prep Compound Name [M + 1] + Comments 17 4-Benzo[b]thiophen-7-yl-pyridine 212 Heat at 100° C. catalyst Pd(PPh 3 ) 4 Preparation 18 4-Benzo[b]thiophen-7-yl-2-fluoro-5-methyl-pyridine In a flask, combine 2-fluoro-4-iodo-5-methyl-pyridine (355 mg, 1.5 mmol), 2-benzo[b]thiophen-7-yl-4,4,5,5-tetramethyl-[1,3,2]dioxaborolane (282 mg, 1.8 mmol), [1,1′-bis(diphenylphosphino)ferrocene]dichloropalladium(II), complex with dichloromethane (1:1) (61 mg, 0.07 mmol), 2-(di-tert-butylphosphino)biphenyl (13 mg, 0.04 mmol), sodium carbonate (2 M, 1.5 mL, 3 mmol) and THF (10 mL). Heat the mixture at 100° C. for 3 hours in an oil bath. Dilute the mixture with chloroform/isopropanol (3/1). Wash the solution with saturated aqueous sodium chloride. Dry over sodium sulfate. Concentrate in vacuo to a dark residue. Purify by column chromatography (20% ethyl acetate in hexane) to afford the title compound (300 mg, 82%) as yellow oil. MS (ES) m/z 244 [M+1] + . Prepare the following intermediates essentially according to the preparation of 4-benzo[b]thiophen-7-yl-2-fluoro-5-methyl-pyridine using the appropriate starting material. Physical Data MS (ES) m/z Prep Compound Name [M + 1] + Comments 19 (4-Benzo[b]thiophen-7-yl-6-fluoro- 345 N 2 pyridin-3-yl)-carbamic acid atmosphere tert-butyl ester 20 4-Benzo[b]thiophen-7-yl-2-fluoro- 345 N 2 pyridin-3-ylamine atmosphere 21 4-Benzo[b]thiophen-7-yl-2-chloro-5- 290 N 2 ethoxy-pyridine atmosphere 22 (4-Benzo[b]thiophen-7-yl-6-fluoro- 345 Deoxygenated pyridin-3-yl)-carbamic acid (N 2 ) tert-butyl ester 23 (4-Benzo[b]thiophen-7-yl- 325 Deoxygenated pyridin-3-yl)-methyl-carbamic acid (N 2 ) tert-butyl ester Preparation 24 4-Benzo[b]thiophen-7-yl-3-methoxymethoxy-pyridine Solution A: Treat a solution of 3-methoxymethoxy-pyridine (2.5 g, 18 mmol) in diethyl ether (90 mL) at −70° C. with tert-butyl lithium (1.7 M in pentane, 10 mL, 18 mmol) dropwise over 10 min. Stir the mixture at −70° C. for 40 min and add a solution of triisopropyl borate (5 mL, 22 mmol) in THF (10 mL) dropwise over 5 min. Stir the mixture at −70° C. for one hour and then remove the ice bath and allow the mixture to slowly warm to room temperature. Solution B: Treat a solution of 7-bromo-benzo[b]thiophene (3.8 g, 18 mmol), 2-(di-tert-butylphosphino)biphenyl (268 mg, 0.90 mmol), [1,1′-bis(diphenylphosphino)ferrocene]dichloropalladium(II), complex with dichloromethane (1:1) (732 mg, 0.90 mmol) in 1,4-dioxane (30 mL) with 2 M aqueous sodium carbonate (72 mL, 36 mmol). Once solution A reaches room temperature, heat the solution to 80° C. Treat solution B with solution A dropwise over 10 min. Heat the combined solution to 85° C. for 5 hours. Cool the mixture to room temperature and dilute with ethyl acetate and water. Wash the organic phase with water and saturated aqueous sodium chloride, dry over sodium sulfate, filter, and concentrate in vacuo. Purify the crude product by column chromatography on 120 g silica gel eluting with a gradient of dichloromethane to ethyl acetate to give the title compound (3.8 g) containing some starting 3-methoxymethoxy-pyridine. Use product without further purification. 1 H NMR (400 MHz, CDCl 3 ) δ 8.68 (s, 1H), 8.42 (d, J=4 Hz, 1H), 7.88 (d, J=8 Hz, 1H), 7.33-7.50 (m, 5H), 5.12 (s, 2H), 3.36 (s, 3H). Preparation 25 2-Chloro-4-[7-(2-chloro-pyridin-4-yl)-benzo[b]thiophen-2-yl]-pyrimidine In a 500 mL round bottom flask, cool a solution of 4-benzo[b]thiophen-7-yl-2-chloro-pyridine (13 g, 53.1 mmol) and triisopropylborate (20 g, 106 mmol) in THF (150 mL) to −70° under nitrogen. To the cooled solution, add lithium diisopropylamide (2 M in THF, 53 mL, 106 mmol) gradually over a period of 30 min. Stir the mixture continually for an additional 1 hour in the cooling bath. Gradually transfer the mixture into a refluxing solution of 2,4-dichloro-pyrimidine (12 g, 106 mmol), [1,1′-bis(diphenyl-phosphino)ferrocene]dichloropalladium(II), complex with dichloromethane (1:1) (2.2 g, 53 mmol) and sodium carbonate (35 mL, 3 M, 106 mmol) in THF (150 mL) over a period of 30 min. Reflux for an additional 1 hour. Cool the mixture to room temperature and dilute with 500 mL of chloroform/isopropanol (3/1) and 200 mL of water. Collect the resulting solid by filtration and reserve the chloroform/isopropanol/water mixture. Wash the solid with dichloromethane and dry it under vacuum. Separate the layers of the chloroform/isopropanol/water mixture. Wash the organic phase with water and saturated aqueous sodium chloride, dry over sodium sulfate and concentrate in vacuo to give a brown residue. Purify the residue by flash column chromatography (10% methanol in dichloromethane) to afford additional product. Combine the two portions to give the title compound (13 g, 68%) MS (ES) m/z 358 [M+1] + . Prepare the following intermediates essentially according to the preparation of 2-chloro-4-[7-(2-chloro-pyridin-4-yl)-benzo[b]thiophen-2-yl]-pyrimidine using the appropriate starting material. Physical Data MS (ES) m/z Prep Compound Name [M + 1] + Comments 26 2-Chloro-5-fluoro-4-(7-pyridin-4-yl- 342 benzo[b]thiophen-2-yl)-pyrimidine 27 2-Chloro-5-methyl-4-(7-pyridin-4-yl- 338 benzo[b]thiophen-2-yl)-pyrimidine 28 2-Chloro-5-fluoro-4-[7-(2-fluoro-5-methyl- 374 pyridin-4-yl)-benzo[b]thiophen-2-yl]-pyrimidine 29 2-Chloro-4-[7-(2-fluoro-5-methyl-pyridin-4-yl)- 370 benzo[b]thiophen-2-yl]-5-methyl-pyrimidine 30 2-Chloro-4-[7-(2-fluoro-5-methyl-pyridin-4-yl)- 356 Additive: benzo[b]thiophen-2-yl]-pyrimidine 2-(di-tert- butylphosphino)biphenyl 31 2-Chloro-5-fluoro-4-[7-(3-methoxymethoxy- 402 pyridin-4-yl)-benzo[b]thiophen-2-yl]-pyrimidine 32 2-Chloro-4-[7-(2-chloro-5-ethoxy-pyridin-4-yl)- 420 benzo[b]thiophen-2-yl]-5-fluoro-pyrimidine 33 {4-[2-(2-Chloro-pyrimidin-4-yl)- 457 benzo[b]thiophen-7-yl]-6-fluoro-pyridin-3-yl}- carbamic acid tert-butyl ester 34 4-(7-Bromo-benzo[b]thiophen-2-yl)-2-chloro-5- 343 fluoro-pyrimidine 35 2,5-Dichloro-4-[7-(2-fluoro-5-methyl-pyridin-4- 390 Additive: yl)-benzo[b]thiophen-2-yl]-pyrimidine 2-(di-tert- butylphosphino)bi- phenyl 36 4-(7-Bromo-benzo[b]thiophen-2-yl)-2-chloro-5- 361 chloro-pyrimidine 37 4-(7-Bromo-benzo[b]thiophen-2-yl)-2-chloro-5- 340 GCMS methyl-pyrimidine (EI) M + 38 4-(7-Bromo-benzo[b]thiophen-2-yl)-2-chloro- 327 pyrimidine Preparation 39 4-[2-(2-Chloro-5-fluoro-pyrimidin-4-yl)-benzo[b]thiophen-7-yl]-pyridin-3-ol Treat a solution of 2-chloro-5-fluoro-4-[7-(3-methoxymethoxy-pyridin-4-yl)-benzo[b]thiophen-2-yl]-pyrimidine (4 g, 10 mmol) in THF (10 mL) with 5 N HCl (3 mL). Stir the mixture at room temperature for 6 hours. Concentrate the reaction in vacuo and dilute with saturated aqueous sodium bicarbonate and dichloromethane. Separate the layers and filter each layer. Wash the solid from the organic phase with dichloromethane to give the title compound (300 mg) as a tan solid. Wash the solid from the aqueous layer with water and dry to give the title compound (300 mg) as a tan solid. Combine the solids to give the title compound (600 mg, 17%) as a tan solid. MS (ES) m/z 358 [M+1] + . Preparation 40 2-Chloro-4-[7-(3-ethoxy-pyridin-4-yl)-benzo[b]thiophen-2-yl]-5-fluoro-pyrimidine Treat a solution of 4-[2-(2-chloro-5-fluoro-pyrimidin-4-yl)-benzo[b]thiophen-7-yl]-pyridin-3-ol (100 mg, 0.28 mmol) and cesium carbonate (100 mg, 0.28 mmol) in dimethylformamide (1 mL) with ethyl iodide (44 mg, 0.28 mmol). Stir the mixture at room temperature for 12 hours. Dilute the mixture with ethyl acetate and wash the solution with three portions of water, one portion of saturated aqueous sodium chloride, dry over sodium sulfate, filter, and concentrate in vacuo. Purify the crude product by column chromatography on 12 g silica gel eluting with a gradient of dichloromethane to ethyl acetate to give the title compound (48 mg, 45%) as a brown solid. MS (ES) m/z 386 [M+1] + . Preparation 41 2-Chloro-5-fluoro-4-[7-(3-methoxy-pyridin-4-yl)-benzo[b]thiophen-2-yl]-pyrimidine Prepare the title compound essentially according to the preparation of 2-chloro-4-[7-(3-ethoxy-pyridin-4-yl)-benzo[b]thiophen-2-yl]-5-fluoro-pyrimidine using the appropriate starting material. MS (ES) m/z 372 [M+1] + Preparation 42 1-{2-[4-(7-Bromo-benzo[b]thiophen-2-yl)-5-fluoro-pyrimidin-2-ylamino]-ethyl}-imidazolidin-2-one Combine 1-(2-aminoethyl)-2-imidazolone (100 g, 774 mmol) with 4-(7-bromo-benzo[b]thiophen-2-yl)-2-chloro-5-fluoro-pyrimidine (90 g, 262 mmol) in 1,4-dioxane (650 mL) and heat to 90° C. with stirring under nitrogen for 3 hours. Cool the reaction to room temperature. Filter and wash the solid with water (3×500 mL) and diethyl ether (500 mL). Vacuum-dry at 50° C. to give the title compound (59.2 g, 52%) as a yellow solid. MS (ES) m/z 436 [M+1] + . Prepare the following intermediates essentially according to the preparation of 1-{2-[4-(7-bromo-benzo[b]thiophen-2-yl)-5-fluoro-pyrimidin-2-ylamino]-ethyl}-imidazolidin-2-one using the appropriate starting material. Physical Data MS (ES) m/z Prep Compound name [M + 1] + 43 1-{2-[4-(7-Bromo-benzo[b]thiophen-2-yl)-5-chloro- 454 pyrimidin-2-ylamino]-ethyl}-imidazolidin-2-one 44 1-{2-[4-(7-Bromo-benzo[b]thiophen-2-yl)-5-methyl- 432 pyrimidin-2-ylamino]-ethyl}-imidazolidin-2-one 45 1-{2-[4-(7-Bromo-benzo[b]thiophen-2-yl)-pyrimidin-2- 420 ylamino]-ethyl}-imidazolidin-2-one Preparation 46 5-Bromomethyl-2-fluoro-4-iodo-pyridine In a flask, combine 2-fluoro-4-iodo-picoline (10.0 g, 42.19 mmol), N-bromosuccinimide (9.76 g, 54.85 mmol), 2,2′-azobisisobutyronitrile (3.46 g, 21.10 mmol) and dry CCl 4 (100 mL). Heat at 70° C. under nitrogen for 16 hours. Cool to room temperature. Dilute with dichloromethane and wash with water and saturated aqueous sodium chloride. Separate the layers and dry the organic layer over magnesium sulfate. Concentrate in vacuo to give crude product. Purify by column chromatography (1% to 15% ethyl acetate in hexane) to afford the title compound (8.27 g, 62%). MS (EI) m/z 315M. Preparation 47 1-(2-{5-Fluoro-4-[7-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-benzo[b]thiophen-2-yl]-pyrimidin-2-ylamino}-ethyl)-imidazolidin-2-one Combine 1-{2-[4-(7-bromo-benzo[b]thiophen-2-yl)-5-fluoro-pyrimidin-2-ylamino]-ethyl}-imidazolidin-2-one (5.5 g, 12.6 mmol), bis(pinacolato)diboron (3.84 g, 15.3 mmol), (1,1′-bis(diphenylphosphino)-ferrocene)dichloropalladium(II) (1.0 g, 1.3 mmol), potassium acetate (2.5 g, 25 mmol) in DMSO (80 mL) in a flask. Bubble nitrogen through the mixture for 10 min. Seal the flask and put it into an oil bath to heat at 85° C. overnight. Dilute the mixture with chloroform/isopropyl alcohol (3/1). Wash the solution with saturated aqueous sodium chloride. Dry it over sodium sulfate. Concentrate the solution in vacuo to a dark residue. Purify the residue by column chromatography (hexane→20% ethyl acetate in hexane→10% methanol in dichloromethane) to afford the product as a brown solid (5 g, 82%). MS (ES) m/z 484 [M+1] + . Preparation 48 (6-Fluoro-4-iodo-pyridin-3-yl)-methanol Combine 5-bromomethyl-2-fluoro-4-iodo-pyridine (0.9 g, 2.85 mmol), nitromethane (15 mL, 278 mmol), silver tetrafluoroborate (721 mg, 3.7 mmol), and dimethylformamide (5 mL) in a round bottom flask. Stir the mixture overnight at room temperature. Add sodium carbonate (1.81 g, 17.1 mmol) and methanol (10 mL) into the mixture. Stir at room temperature for another 4 hours. Dilute the reaction mixture with chloroform, and wash with water and saturated aqueous sodium chloride. Separate the organic layer from the aqueous layer and dry over MgSO 4 . After filtration, evaporate the organic solvent in vacuo to give the crude product. Purify the crude with flash column chromatography (eluted with 10% methanol in dichloromethane) to give the desired product (0.6 g, 83%). MS (ES) m/z 254 [M+1] + . Preparation 49 2-Fluoro-5-fluoromethyl-4-iodo-pyridine Add diethylaminosulfur trifluoride (892 mg, 4 mmol) drop-wise to a solution of (6-fluoro-4-iodo-pyridin-3-yl)-methanol in dichloromethane (25 mL) in a round bottom flask under nitrogen, and then add ethanol (0.3 mL) at 0-5° C. Stir the mixture for 3 hours. Pour the reaction mixture into saturated sodium bicarbonate solution. Abstract the product into chloroform, and wash with water and saturated aqueous sodium chloride. Separate the organic layer from the aqueous layer and dry over MgSO 4 . After filtration, evaporate the organic solvent in vacuo to give a crude product. Purify the crude with flash column chromatography (10% methanol in dichloromethane) to give the title compound (0.32 g, 53%). MS (ES) m/z 256 [M+1] + . EXAMPLES Example 1 1-(2-{4-[7-(2-Chloro-pyridin-4-yl)-benzo[b]thiophen-2-yl]pyrimidin-2-ylamino}ethyl)imidazolidin-2-one Combine 2-chloro-4-[7-(2-chloro-pyridin-4-yl)-benzo[b]thiophen-2-yl]-pyrimidine (9 g, 25.1 mmol) and 2-(amino-ethyl)-1,3-dihydro-imidazol-one (6.4 g, 50.2 mmol) in n-butanol (200 mL) in a pressure vessel. Heat the mixture in an oil bath at 120° C. for 5 hours. Dilute the mixture with chloroform/isopropanol (3/1). Wash the solution with saturated aqueous sodium chloride. Dry it over sodium sulfate. Concentrate the solution in vacuo to a dark residue. Purify by column chromatography (dichloromethane to 10% methanol in dichloromethane) to afford the title compound (9 g, 93%) as a yellow solid. MS (ES) m/z 451 [M+1] + . Prepare the following examples essentially according to the preparation of 1-(2-{4-[7-(2-chloro-pyridin-4-yl)-benzo[b]thiophen-2-yl]pyrimidin-2-ylamino}-ethyl)-imidazolidin-2-one using the appropriate starting material. Physical Data MS (ES) m/z Ex Compound name Structure [M + 1] + Comments 2 1-(2-{5-Fluoro-4- [7-(2-fluoro-5- methylpyridin-4- yl)- benzo[b]thiophen- 2-yl]-pyrimidin-2- ylamino}ethyl) imidazolidin-2-one 467 Microwave, 1,4-dioxane- NMP 120° C. 3 1-(2-{4-[7-(2- Fluoro-5- methylpyridin-4- yl)- benzo[b]thiophen- 2-yl]-5- methylpyrimidin- 2- ylamino}ethyl) imidazolidin-2-one 463 Microwave, 1,4-dioxane- NMP 120° C. 4 1-(2-{4-[7-(2- Fluoro-5- methylpyridin-4- yl)- benzo[b]thiophen- 2-yl]pyrimidin-2- ylamino}- ethyl)imidazolidin- 2-one 449 Additive: Triethyl amine-3 equivalents 5 1-{2-[5-Methyl-4- (7-pyridin-4-yl- benzo[b]thiophen- 2-yl)pyrimidin-2- ylamino]- ethyl}imidazolidin- 2-one 431 Microwave, NMP 120° C. 6 1-(2-{5-Chloro-4- [7-(2-fluoro-5- methylpyridin-4- yl)benzo[b]thiophen- 2-yl]- pyrimidin-2- ylamino}ethyl) imidazolidin-2-one 483 Additive: Triethyl amine-3 equivalents 7 1-{2-[5-Fluoro-4- (7-pyridin-4-yl- benzo[b]thiophen- 2-yl)pyrimidin-2- ylamino]- ethyl}imidazolidin- 2-one 435 Microwave, NMP 120° C. 8 1-(2-{4-[7-(3- Ethoxypyridin-4- yl)- benzo[b]thiophen- 2-yl]-5- fluoropyrimidin- 2- ylamino}ethyl) imidazolidin-2-one 479 9 1-(2-(5-Fluoro-4- (7-(3- hydroxypyridin-4- yl)benzo[b]thiophen- 2-yl)pyrimidin- 2- ylamino)ethyl) imidazolidin-2-one 451 10 1-(2-{4-[7-(2- Chloro-5- ethoxypyridin-4- yl)- benzo[b]thiophen- 2-yl]-5- fluoropyrimidin- 2-ylamino}- ethyl)imidazolidin- 2-one 513 11 1-(2-{5-Fluoro-4- [7-(3- methoxypyridin- 4-yl)- benzo[b]thiophen- 2-yl]pyrimidin-2- ylamino}- ethyl)imidazolidin- 2-one 465 Example 12 1-(2-(5-Chloro-4-(7-(pyridin-4-yl)benzo[b]thiophen-2-yl)pyrimidin-2-ylamino)ethyl)imidazolidin-2-one Combine 1-{2-[4-(7-bromo-benzo[b]thiophen-2-yl)-5-chloro-pyrimidin-2-ylamino]-ethyl}-imidazolidin-2-one (81.6 mg, 0.18 mmol), pyridine-4-boronic acid (36.8 mg, 0.3 mmol), and sodium bicarbonate (18.1 mg, 0.2 mmol) in a mixture of water (1 mL) and DMSO (1 mL). Add tetrakis(triphenylphosphine)palladium(0) (10.4 mg, 0.009 mmol). Irradiate the mixture at 150° C. for 15 min with magnetic stirring. Pour the crude reaction mixture onto a strong cation exchange (SCX) (10 g) column. Elute the desired product with 2 N ammonia in methanol (40 mL) and concentrate under reduced pressure. Purify by reverse phase chromatography (30 to 90% gradient at 80 mL/min for 11 min on a 30×100 mm, 5 mm, C 18 MS Xterra® column, Solvent A: water with 0.01 M ammonium bicarbonate, Solvent B: acetonitrile) to afford the title compound (20.4 mg, 25.1%). MS (ES) m/z 451 [M+1] + . Example 13 1-(2-{5-Chloro-4-[7-(5-chloro-2-fluoropyridin-4-yl)-benzo[b]thiophen-2-yl]pyrimidin-2-ylamino}ethyl)imidazolidin-2-one In a microwave vial, combine 1-{2-[4-(7-bromo-benzo[b]thiophen-2-yl)-5-chloro-pyrimidin-2-ylamino]-ethyl}-imidazolidin-2-one (500 mg, 1.1 mmol), 5-chloro-2-fluoropyridine-4-boronic acid (578 mg, 3.3 mmol), [1,1′-bis(diphenylphosphino) ferrocene]dichloropalladium(II), complex with dichloromethane (1:1) (90 mg, 0.11 mmol), 2-(di-tert-butylphosphino)biphenyl (20 mg, 0.066 mmol) and sodium carbonate (350 mg, 3.3 mmol) in THF (3 mL) and water (1.5 mL). Bubble nitrogen through the mixture for 5 min. Heat the mixture to 100° C. for 10 min. Concentrate the organic layer to dryness in vacuo. Slurry the resulting solid into dichloromethane/methanol and purify by column chromatography (1% 2 N ammonia/methanol solution in dichloromethane to 10% 2 N ammonia/methanol solution in dichloromethane) to afford the title compound. For further purification, dissolve the product in DMSO and purify by reverse phase column chromatography (50% acetonitrile in water (with 0.03% HCl) to 95% acetonitrile in water (with 0.03% HCl) to afford the title compound (146 mg, 26%). MS (ES) m/z 503 [M+1] + . Prepare the following examples essentially according to the preparation of 1-(2-{5-chloro-4-[7-(5-chloro-2-fluoropyridin-4-yl)benzo[b]thiophen-2-yl]-pyrimidin-2-ylamino}ethyl)imidazolidin-2-one using the appropriate starting material. Physical Data MS (ES) m/z Ex Compound Name Structure [M + 1] + Comments 14 1-(2-{4-[7-(2- Chloro-pyridin- 4-yl)- benzo[b]thiophen- 2-yl]-5- fluoropyrimidin- 2- ylamino}ethyl) imidazolidin-2- one 469 15 1-(2-{5-Chloro- 4-[7-(2-chloro- pyridin-4- yl)benzo[b] thiophen-2- yl]pyrimidin-2- ylamino}ethyl) imidazolidin-2- one 486 16 1-(2-{4-[7-(5- Chloro-2- fluoro-pyridin- 4-yl)- benzo[b]thiophen- 2-yl]-5- fluoropyrimidin- 2- ylamino}ethyl) imidazolidin-2- one 487 Purify by reverse phase, CH 3 CN and water 17 1-(2-{4-[7-(2- Chloro-5- fluoropyridin- 4-yl)- benzo[b]thiophen- 2-yl]-5- fluoropyrimidin- 2- ylamino}-ethyl) imidazolidin-2- one 487 Purify by reverse phase, CH 3 CN and water 18 1-(2-{4-[7-(3- Chloro-pyridin- 4-yl)- benzo[b]thiophen- 2-yl]-5- fluoropyrimidin- 2- ylamino}ethyl) imidazolidin-2- one 469 Purify by reverse phase, CH 3 CN and water 19 1-(2-{5-Fluoro- 4-[7-(3- methylpyridin- 4-yl)- benzo[b]thiophen- 2- yl]pyrimidin-2- ylamino}ethyl) imidazolidin-2- one 449 Purify on reverse phase, CH 3 CN and water 20 1-(2-{4-[7-(5- Chloro-2- fluoropyridin- 4-yl)- benzo[b]thiophen- 2-yl]-5- methylpyrimidin- 2- ylamino}ethyl) imidazolidin-2- one 483 Purify on reverse phase, CH 3 CN and water 21 1-(2-{4-[7-(2,5- Dichloropyridin- 4-yl)- benzo[b]thiophen- 2-yl]-5- fluoropyrimidin- 2- ylamino}ethyl) imidazolidin-2- one 503 22 1-(2-{5-Fluoro- 4-[7-(2- fluoropyridin-4- yl)- benzo[b]thiophen- 2- yl]pyrimidin-2- ylamino}ethyl) imidazolidin-2- one 453 23 1-(2-{4-[7-(5- Chloro-2- fluoro-pyridin- 4-yl)- benzo[b]thiophen- 2- yl]pyrimidin- 2- ylamino}ethyl) imidazolidin-2- one 469 Example 24 4-(2-(2-(2-(2-Oxoimidazolidin-1-yl)ethylamino)pyrimidin-4-yl)benzo[b]thiophen-7-yl)picolinonitrile Combine 1-(2-{4-[7-(2-chloro-pyridin-4-yl)-benzo[b]thiophen-2-yl]-pyrimidin-2-ylamino}-ethyl)-imidazolidin-2-one (100 mg, 0.22 mmol), zinc cyanide (51 mg, 0.44 mmol), tris(dibenzylideneacetone)dipalladium(0) (10 mg, 0.01 mmol), 1,1′-bis(diphenylphosphino)-ferrocene (6 mg, 0.01 mmol) in DMSO (6 mL). Heat the mixture at 100° C. for 4 hours. Cool the mixture to room temperature and load onto a silica column. Elute the column with 10% methanol in dichloromethane to afford the title compound (0.7 g, 72%) as yellow oil. MS (ES) m/z 442 [M+1] + . Example 25 1-(2-{4-[7-(3-Amino-pyridin-4-yl)benzo[b]thiophen-2-yl]-5-fluoropyrimidin-2-ylamino}ethyl)imidazolidin-2-one Combine N-{4-[2-(2-chloro-5-fluoro-pyrimidin-4-yl)-benzo[b]thiophen-7-yl]-pyridin-3-yl}-2,2-dimethyl-propionamide (330 mg, 0.75 mmol), 2-(amino-ethyl)-1,3-dihydro-imidazolone (386 mg, 3.0 mmol), and 1,4-dioxane (6 mL) in a capped vial and heat at 85° C. for 4 hours. Concentrate in vacuo. Dilute the mixture with dichloromethane and water. Wash the organic solution with water. Dry the organic solution over sodium sulfate. Filter and concentrate the solution in vacuo to a dark residue. Purify by column chromatography (dichloromethane to 7% methanol in dichloromethane) to afford N-[4-(2-{5-fluoro-2-[2-(2-oxo-imidazolidin-1-yl)-ethylamino]-pyrimidin-4-yl}-benzo[b]thiophen-7-yl)-pyridin-3-yl]-2,2-dimethyl-propionamide. Transfer the amide intermediate to a 40 mL septum capped vial. Add a magnetic stir bar and charge water (20 mL) and concentrated H 2 SO 4 (5 mL) to the vial. Warm the vial to 90° C. in an oil bath for 5 hours. Cool the reaction to room temperature and pass through an SCX (10 g) column. Elute with water/methanol 1:1, then 100% methanol, then 1:1 dichloromethane/methanol, and finally elute the product off with 10% 2 M ammonia in methanol/90% dichloromethane. Concentrate in vacuo. Chromatograph on silica (80 g) eluting with gradient of 0% to 10% 2 M ammonia/methanol solution in dichloromethane. Dry in vacuum oven at 42° C. for 2 hours to give the title compound (192.6 mg, 48%) as a gold solid. MS (ES) m/z 450 [M+1] + . Prepare the following examples essentially according to the preparation of 1-(2-{4-[7-(3-amino-pyridin-4-yl)benzo[b]thiophen-2-yl]-5-fluoropyrimidin-2-ylamino}-ethyl)imidazolidin-2-one using the appropriate starting material. Physical Data MS (ES) m/z Ex Compound name Structure [M + 1] + 26 1-(2-{4-[7-(3- Methylamino-pyridin- 4- yl)benzo[b]thiophen- 2-yl]pyrimidin-2- ylamino}ethyl) imidazolidin-2-one 446 27 1-(2-{4-[7-(3-Amino- pyridin-4- yl)benzo[b]thiophen- 2-yl]-5- methylpyrimidin-2- ylamino}ethyl) imidazolidin-2-one 446 28 1-(2-{4-[7-(3-Amino- pyridin-4- yl)benzo[b]thiophen- 2-yl]-pyrimidin-2- ylamino}ethyl) imidazolidin-2-one 432 Example 29 1-(2-{4-[7-(5-Amino-2-fluoropyridin-4-yl)benzo[b]thiophen-2-yl]pyrimidin-2-ylamino}ethyl)imidazolidin-2-one Combine {4-[2-(2-chloro-pyrimidin-4-yl)-benzo[b]thiophen-7-yl]-6-fluoro-pyridin-3-yl}-carbamic acid tert-butyl ester (813 mg, 1.77 mmol), 2-(amino-ethyl)-1,3-dihydro-imidazol-one (919 mg, 7.11 mmol), and 1,4-dioxane (22 mL) in a capped vial and heat at 70° C. for 15 hours. Concentrate in vacuo. Dilute the mixture with dichloromethane and water. Wash the organic solution with water. Dry the organic solution over sodium sulfate. Filter and concentrate the solution in vacuo to a dark residue. Purify by column chromatography (dichloromethane to ethyl acetate) to afford [6-fluoro-4-(2-{2-[2-(2-oxo-imidazolidin-1-yl)-ethylamino]-pyrimidin-4-yl}-benzo[b]thiophen-7-yl)-pyridin-3-yl]-carbamic acid tert-butyl ester. Dissolve the [6-fluoro-4-(2-{2-[2-(2-oxo-imidazolidin-1-yl)-ethylamino]-pyrimidin-4-yl}-benzo[b]thiophen-7-yl)-pyridin-3-yl]-carbamic acid tert-butyl ester into dichloromethane and adsorb onto silica gel (10 g) via concentration in vacuo. Dry under high vacuum for 24 hours. Place silica gel into a round bottom flask and heat in a temperature controlled oil bath to 98-99° C. while under high vacuum for 2 hours. Cool to room temperature. Extract product from silica gel with 10% 7 N ammonia in methanol/90% dichloromethane. Concentrate in vacuo. Chromatograph on silica eluting with a gradient of 100% dichloromethane to 7% 2 N ammonia in methanol/93% dichloromethane to afford the title compound (65.2 mg, 8.2%). MS (ES) m/z 450 [M+1] + . Example 30 1-(2-{4-[7-(3-Amino-2-fluoropyridin-4-yl)benzo[b]thiophen-2-yl]pyrimidin-2-ylamino}ethyl)imidazolidin-2-one Prepare the title compound essentially according to the preparation of 1-(2-{4-[7-(5-amino-2-fluoro-pyridin-4-yl)-benzo[b]thiophen-2-yl]-pyrimidin-2-ylamino}-ethyl)-imidazolidin-2-one using the appropriate starting material. MS (ES) m/z 450 [M+1] + . Example 31 1-(2-{5-Fluoro-4-[7-(2-fluoro-5-hydroxymethyl-pyridin-4-yl)benzo[b]thiophen-2-yl]pyrimidin-2-ylamino}ethyl)imidazolidin-2-one Combine 1-(2-{5-fluoro-4-[7-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-benzo[b]thiophen-2-yl]-pyrimidin-2-ylamino}-ethyl)-imidazolidin-2-one (120 mg, 0.25 mmol), (6-fluoro-4-iodo-pyridin-3-yl)-methanol (100 mg; 0.32 mmol), (1,1′-bis(di-phenylphosphino)ferrocene)palladium(II) chloride (10.14 mg; 0.01 mmol), 2-(di-tert-butylphosphino)biphenyl (2 mg, 0.01 mmol) and sodium carbonate (2 M, 0.2 mL, 0.4 mmol) in 5 mL of dioxane in a pressure tube. Heat the mixture at 100° C. overnight in oil bath. Cool the mixture down to room temperature, dilute it with chloroform-isopropyl alcohol (3/1). Wash the organic phase with saturated aqueous sodium chloride, dry it over sodium sulfate and concentrate it to an oily residue. Purify the crude by flash column chromatography (10% methanol in dichloromethane) to afford the title compound (25 mg, 21%). MS (ES) m/z 483 [M+1] + . Example 32 1-(2-{5-Fluoro-4-[7-(2-fluoro-5-(fluoromethyl)pyridin-4-yl)benzo[b]thiophen-2-yl]pyrimidin-2-ylamino}ethyl)imidazolidin-2-one Combine 1-(2-{5-fluoro-4-[7-(4,4,5,5-tetramethyl-[1,3,2]dioxaborolan-2-yl)-benzo[b]thiophen-2-yl]-pyrimidin-2-ylamino}-ethyl)-imidazolidin-2-one (120 mg, 248.26 μmol), 2-fluoro-5-fluoromethyl-4-iodo-pyridine (100 mg, 392.15 μmol) tris(dibenzylideneacetone)dipalladium (0) (11.37 mg, 12.41 μmol) tricyclohexylphosphine (2.09 mg, 7.45 μmol), potassium phosphate (105.39 mg, 496.51 μmol) in 5 mL of dioxane in a sealed pressure tube. Heat the mixture at 100° C. for 3 hours in the oil bath. LC-MS shows a peak at 485. Cool the reaction mixture down to room temperature and dilute it with chloroform-isopropyl alcohol (3/1). Wash the organic solution with saturated aqueous sodium chloride, dry it over sodium sulfate and concentrate it to crude. Purify the crude by flash chromatography (10% methanol in dichloromethane) to give the target product (70 mg, 58.2%). MS (ES) m/z 485 [M+1] + . Assays Plk1 has been shown to be over expressed in many human tumors, such as non-small cell lung, oropharyngeal, oesophageal, gastric, melanoma, breast, ovarian, endometrial, colorectal, glioblastoma, papillary, pancreatic, prostate, hepatoblastoma and non-Hodgkin lymphoma cancers. Furthermore, Plk1 expression has prognostic significance in non-small cell lung, oropharyngeal, oesophageal, melanoma, colorectal, hepatoblastoma and non-Hodgkin lymphoma cancers (Strebhardt, K. and A. Ullrich (2006). Nature Reviews Cancer 6(4): 321-30). Plk1 phosphorylated substrates regulate progression of mitosis by coordinating centrosome maturation, entry into mitosis, sister chromatid separation and cytokinesis (Eckerdt and Strebhardt 2006; Strebhardt and Ullrich 2006; van de Weerdt, B. C. and R. H. Medema (2006). Cell Cycle 5(8): 853-64). Inhibiting Plk1 function using antibody injection, expression of a dominant negative Plk1, and antisense mRNA reduction produces monopole spindles and anaphase arrest leading to mitotic cell death in tumor cell lines but reversible G2 arrest in normal non-transformed primary cell lines. Additionally, it has been reported that Plk may be useful in the treatment of rhabdoid tumors, (Morozov A., et al., Clinical Cancer Research. 13(16):4721-30, (Aug. 15, 2007). BI-2536 has demonstrated activity in preclinical models using HCT116, A549 and NCIH460 murine xenografts (Baum, A., P. Garin-Chesa, et al. (2006). # C 191 In vivo activity of BI 2536, a potent and selective inhibitor of the mitotic kinase PLK 1, in a range of cancer xenografts . AACR-NCI-EORTC International Conference on “Molecular Targets and Cancer Therapeutics”, Philadelphia, Pa.). The results of the following assays demonstrate evidence that the compounds of the present invention are useful as anticancer agents. Expression and Purification of Plk1 Human Plk1 cDNA, which may be obtained from a number of sources, such as Incyte (accession number: NM — 005030), may be directly linked at one of its termini with a polynucleotide sequence expressing a His 6 tag, such as the C-terminal FLAG-His 6 tag, and inserted into an appropriate expression vector, such as a pFastBac™ vector (Invitrogen) and transfected into an appropriate system, such as baculovirus similar to what has been reported by Yue-Wei Qian, et al., Science 282, 1701 (1998) for xPlkk1. If a viral expression system is used, then the virus (e.g., baculovirus bearing a Plk1-Flag-His 6 tag polynucleotide construct) is infected into a culture of a suitable host cell, such as Sf9 cells. When sufficient amounts of the Plk1-Flag-His 6 tag fusion protein have been expressed, for example, at about 46 hours after infection, the culture should be treated with okadaic acid (0.1 μM) for a sufficient period of time (e.g., 3 hours). The Plk1-Flag-His 6 tag fusion is purified from cell pellets using a metal affinity resin, such as TALON™ (Clontech, Catalog # 635503) using methods well known in the art. Purified Plk1-Flag-His 6 tag fusion is stored in a suitable medium, such as 10 mM HEPES, 150 mM NaCl, 0.01% TRITON® X-100, 1 mM dithiothreitol (DTT), 10% glycerol, pH 7.5, at −80° C. in small aliquots until use. The identity of the purified Plk1-Flag-His 6 tag fusion protein is confirmed by MALDI (Matrix-Assisted Laser Desorption/Ionization). Expression and Purification of GST-Cdc25C(1-206) Human Cdc25C cDNA, which may be obtained from any appropriate source, such as Incyte (accession number: AY497-474), may be expressed in any convenient expression system, after which purification is effected by well known methods similar to that described by Bin Ouyang et al, Oncogene, 18, 6029-6036 (1999). One convenient system involves overnight growth at 18° C. of E. coli BL21 transformed with the pGEX-2T vector (Amersham) into which the cDNA for human Cds25C has been engineered for induced expression using 1 mM isopropyl-beta-D-thiogalactopyranoside. The expressed GST-Cdc25C(1-206), the substrate for Plk1, may be purified by GLUTATHIONE SEPHAROSE® 4B and stored in an appropriate solution, such as 10 mM HEPES, 100 mM NaCl, pH 7.5 in small aliquots at −80° C. Plk1 Inhibition Assay Plk1 kinase reactions contain Plk1-Flag-His 6 tag fusion enzyme (0.2 ng/μL) in a buffer containing 50 mM HEPES, pH 7.3, 1.0 mM dithiothreitol, 5.0 μM ATP, 10 mM MgCl 2 , 0.01% TRITON® X-100, 0.4 μCi 33 P-ATP, and 0.06 μg/μL GST-Cdc25c (1-206) peptide. Compounds are provided as 10 mM stocks in DMSO. Compounds are serially diluted 1:3 in 20% DMSO to create a 10-point concentration-response curve and subsequently are diluted 1:5 (20 μM to 0.001 μM final in 4% final DMSO concentration) in the reaction mixture to determine compound activity. The reaction is carried out at room temperature for 60 min and then quenched by adding 60 μL of 10.0% H 3 PO 4 . The reaction mixture (85 μL) is transferred to a 96 well phosphocellulose filter plate pre-wetted with 30 μL of 10.0% H 3 PO 4 , incubated at room temperature for 20-30 min and then washed 3× with 0.5% H 3 PO 4 . Wells are dried before addition of 40 μL of MicroScint™20 (Packard) and then counted on a Wallac MICROBETA® Jet. The percentage inhibition values from the 10-point concentration response data are subsequently analyzed, for example, using ACTIVITY BASE™ software (IDBS), using a 4-parameter logistic equation. Absolute IC 50 values are calculated from the resulting curve fit. All exemplified compounds have an IC 50 less than 100 nM with a Minimum Significant Ratio (MSR) of 3.6. For example, Example 13 has an IC 50 of about 23 nM. pHH3(S10), Mitotic Cells, and DNA Content Assays HeLa Cells from the American Type Culture Collection (ATCC) are plated at 200 cells/well in 96 well Beckman Dickinson BIOCOAT™ plates, and are incubated in MEM (Minimum Essential Medium, e.g., GIBCO, catalog #11095) with 10% FBS (Fetal Bovine Serum) in 37° C., 5% CO 2 for 24 hours. Cells are treated by adding compound (in 0.25% DMSO) to the medium, dosing at 10 points across the range 0.5 μM to 0.0098 μM. After 23 hours exposure to the compounds, cells are fixed, for example with the PREFER™ fixative [Anatech LTD., Catalog #414] for 30 min then are permeabilized with 0.1% TRITON® X100 in phosphate buffered saline (PBS) solution for 15 min. Cells are washed 3 times with PBS then digested with 50 μg/mL RNAse. Primary antibody, phosphohistone H3 (Upstate Cat#06-570), is added at 1:500 in PBS with 1% bovine serum albumin (BSA) to the cells over night at 4° C. After 3 PBS washes, cells are incubated with Alexa488 labeled secondary antibody (Invitrogen cat #A11008) for 1 hour at room temperature. Again they are washed 3 times with PBS, and then 15 μM propidium iodide (Molecular Probes cat #P3566) is added for 30 min to stain nuclei. Fluorescence Plates are scanned with ACUMEN EXPLORER™ [Laser-scanning fluorescence microplate cytometer (comprising of 488 nm argon ion laser excitation and multiple photomultiplier tube detection), manufactured by TTP LABTECH LTD] to measure phosphohistone H3, DNA content and mitotic cells as measured by DNA condensation. Image analyses are based on cellular fluorescent signals for identifying cells in different subpopulations. pHH3(S10) positive cells are identified by mean intensity at 500-530 nm above the threshold. Total intensity at 655-705 nm from propidium iodide/DNA is used to identify individual cells (cells with DNA content from 2N to 4N) and subpopulations in cell cycle (2N cells, 4N cells). Peak intensity at 575-640 nm is used to identify DNA condensation that is used as the marker to identify mitotic cells among 4N cells. Assay outputs are percentage of each identified subpopulations, % pHH3, % 2N, % 4N, % mitotic and total cell number. The EC 50 is determined by curve fitting to a four parameter logistic for each output using ACTIVITY BASE™. The resulting EC 50 s for PHH3(s10), DNA content, and mitotic have an MSR of 2.6, 2.4 and 2.5, respectively. For example, Example 13 has a pHH3(s10) EC 50 =42 nM (n=2), DNA content EC 50 =40 nM (n=2) and mitotic EC 50 =45 nM (n=1). Antiproliferative Assay The effects of compounds on cell proliferation can be determined using cells and cell proliferation methods well-known in the art (Robert C. Squatrito et al., Gynecological Oncology, 58, 101-105, (1995)). For example, HCT116 cells, which may be obtained from the American Type Culture Collection, may be seeded at 2000 cells/well in 96-well plates and allowed to attach overnight in a humidified CO 2 incubator at 37° C. Following the 20-24 hour incubation, half-log serially diluted compounds are added and the plates are returned to the incubator. After an appropriate length of exposure (e.g., 72 hours), cell proliferation is estimated using well-known methods. In one method, 10 μL of a tetrazolium salt, such as Alamar Blue™ is added to the cell plates. After an appropriate exposure to the dye, fluorescence (530 nm excitation, 580 nm emission) is determined. The resulting IC 50 has an MSR of 3.1. For example, Example 13 has an IC 50 of 11 nM (n=3). The compounds of the present invention are preferably formulated as pharmaceutical compositions administered by a variety of routes. Most preferably, such compositions are for oral administration. Such pharmaceutical compositions and processes for preparing same are well known in the art. See, e.g., REMINGTON: THE SCIENCE AND PRACTICE OF PHARMACY (A. Gennaro, et al., eds., 19 th ed., Mack Publishing Co., 1995). The compounds of Formula I are generally effective over a wide dosage range. For example, dosages per day normally fall within the range of about 0.01 to about 20 mg/kg of body weight, more preferably 0.1 to 20 mg/kg of body weight. In some instances dosage levels below the lower limit of the aforesaid range may be more than adequate, while in other cases still larger doses may be employed without causing any harmful side effect, and therefore the above dosage range is not intended to limit the scope of the invention in any way. It will be understood that the amount of the compound actually administered will be determined by a physician, in the light of the relevant circumstances, including the condition to be treated, the chosen route of administration, the actual compound or compounds administered, the age, weight, and response of the individual patient, and the severity of the patient's symptoms.
The present invention provides novel imidazolidinonyl aminopyrimidine compounds believed to have clinical use for treatment of cancer through inhibiting Plk1. wherein: R 1 hydrogen, hydroxy, halo, methyl, C 1 -C 2 alkoxy, amino, or methylamino; R 2 is hydrogen, halo, or cyano; R 3 is hydrogen or halo; R 4 is hydrogen, halo, or methyl; provided that at least two of R 1 , R 2 , R 3 , and R 4 are hydrogen; R 5 is hydrogen, halo, or methyl; or a pharmaceutically acceptable salt thereof.
2
[0001] This application claims the benefit of Taiwan application Serial No. 95104406, filed Feb. 9, 2006, the subject matter of which is incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The invention relates in general to a method of channel estimation, and more particularly to a method of channel estimation which requires a small amount of memory and resources. [0004] 2. Description of the Related Art [0005] The orthogonal frequency division multiplexing (OFDM) system having an advantage of preventing multi-path interference resulting in the ghost image is adopted by DVB-T (Digital Video Broadcast Terrestrial) for a high image quality. [0006] In the OFDM system, multi-carrier modulation is performed at the transmitter side and the data are transmitted on sub-carriers through a number of sub-channels. The sub-carriers have different frequencies and are orthogonal to each other such that the data are transmitted at a lower rate in each sub-channel. The characteristics of the transmission channels are time and frequency-dependent. Therefore, the channel response of each sub-channel should be estimated at the receiver side for compensation of the received signals. [0007] Generally speaking, a signal Y ki received via a k th sub-channel at time slot ti can be denoted by: [0000] Y ki =H ki ·X ki +N ki   (1) [0008] Wherein X ki is the signal transmitted via the k th sub-channel at the time slot ti, H ki is the channel response of the k th sub-channel at the time slot ti, and N ki is the noise of the k th sub-channel at the time slot ti. [0009] The channel response H ki could be derived by pilot-based channel estimation. FIG. 1 shows a pilot pattern of the OFDM system. Each circle denotes data transmitted by a sub-channel C( 0 ), C( 1 ), . . . , or C(n) at a time slot t 0 , t 1 , . . . , or tn. Each of the OFDM symbols S(t 0 ), S(t 1 ), . . . , and S(tn) including a number of signals modulated in one of the sub-channels C( 0 ), C( 1 ), . . . , and C(n) is received at each of the time slots t 0 , t 1 , . . . , and tn. The black circle denotes a pilot symbol, and the content and allocation thereof are already known at the receiver side. Therefore, the channel response of each sub-channel could be estimated using the received pilot symbols. [0010] In the estimation of channel response, the influence of noise N ki could be ignored and the estimated channel response could be derived by: [0000] Ĥ ki =Y ki /X ki   (2) [0011] Once the channel responses for the pilot symbols are derived, those for the data symbols could be estimated by linear interpolation. The linear interpolation includes a time-domain interpolation and frequency-domain interpolation. FIG. 2 is a flowchart of a method for estimation of the channel response H 12 of a sub-channel C( 1 ) at a time slot t 2 . The channel response H ki is denoted by A ki *exp(jθ ki ), wherein A is the amplitude and θ is the phase. In step 201 , the amplitude and phase of the response H 32 is obtained. Since the ratio of the interval between the time slots t 2 and t 1 to that between the time slots t 2 and t 5 is 1:3 and the linear interpolation is adopted, the amplitude A 32 at the time slot t 2 is denoted by: [0000] A 32 =( A 31 *¾ +A 35 *¼) [0012] The phase θ 32 is denoted by: [0000] θ 32 =(θ 31 *¾+θ 35 *¼) [0013] In step 203 , the amplitude and phase of the response H 12 is obtained. Since the ratio of difference between the frequencies of the sub-carriers on the sub-channels C( 1 ) and C( 0 ) to that between the frequencies of the sub-carriers on the sub-channels C( 1 ) and C( 3 ) is 1:2, and a linear interpolation is adopted, the amplitude response of the sub-channel C( 1 ) at the time slot t 2 is denoted by: [0000] A 12 =( A 02 *⅔ +A 32 *⅓) [0014] The phase response is denoted by: [0000] θ 12 =(θ 02 *⅔+θ 32 *⅓) [0015] However, in the previously described channel estimation, it is necessary to estimate the channel response of each sub-channel in each time slot at the receiver side, which requires a lot of resources. Besides, a large memory is required for storage of each estimated channel response, which increases the cost. SUMMARY OF THE INVENTION [0016] The invention is directed to a method of channel estimation which requires a small amount of memory and resources. [0017] According to the present invention, a method of channel estimation is provided. The method is applied to a communication system having signals transmitted via a plurality of pilot and non-pilot sub-channels. The method comprising the steps of obtaining a first and second channel responses of each pilot sub-channel using pilot symbols received during a first and second time duration respectively, obtaining an estimated channel response of each pilot sub-channel by averaging the first and second channel responses thereof, and obtaining an estimated channel response of each non-pilot sub-channel by interpolation of those of the pilot sub-channels. [0018] The invention will become apparent from the following detailed description of the preferred but non-limiting embodiments. The following description is made with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0019] FIG. 1 is a pilot pattern of an OFDM system. [0020] FIG. 2 is a flowchart of conventional channel estimation. [0021] FIG. 3 is a flowchart of channel estimation according to a preferred embodiment of the invention. DETAILED DESCRIPTION OF THE INVENTION [0022] A traditional wireless receiver, such as a digital television receiver, has to timely estimate a channel response of the transmission channel due to its time-dependent variation, which thereby requires lots of resources and memory. However, in terms of a home use digital television receiver, the time-dependent variation of channel response is too small to be significant since the location of the TV set is fixed. By this feature, a method of channel estimation for a stationary wireless receiver is provided. The channel response is estimated only when some events occur, such as power on or degradation of signal quality. Only a small amount of resources and memory is required since the operation of channel estimation is simplified. [0023] FIG. 3 is a flowchart of channel estimation according to a preferred embodiment of the invention. The pilot pattern used in the embodiment is the same as that in FIG. 1 . Every four OFDM symbols, such as S(t 0 )˜S(t 3 ), are arranged into a group. The pilot symbols are the same. However the invention is not limited to an OFDM system having four symbols grouped. [0024] In step 301 , a memory is provided for storage of the channel responses. The memory has blocks each of which stores the channel response of one of the sub-channels and has a size the same as that of one OFDM symbol. All the blocks initially store a value of 1. [0025] In step 303 , the memory is updated according to the first received group of OFDM symbols. More specifically, the OFDM symbol received at time t 0 is decoded for estimation of the channel responses of the pilot sub-channels C( 0 ) and C( 12 ) (carrying the pilot symbols). The 0 th and 12 th blocks of the memory are updated by replacing the previously stored values (1 and 1) with the newly estimated channel responses Ĥ 00 and Ĥ 12 0 respectively. The OFDM symbols received at time t 1 are decoded for estimation of the channel responses of the pilot sub-channels C( 0 ), C( 3 ) and C( 15 ). The 0 th , 3 rd and 15 th blocks of the memory are updated by replacing the stored values (Ĥ 00 , 1 and 1) with the newly estimated channel responses Ĥ 01 , Ĥ 31 , and Ĥ 15 1 respectively. The OFDM symbol received at time t 2 is decoded for estimation of the channel responses of the pilot sub-channels C( 0 ), C( 6 ) and C( 18 ). The 0 th , 6 th and 18 th blocks of the memory are updated by replacing the previously stored values (Ĥ 01 , 1 and 1) with the newly estimated channel responses Ĥ 02 , Ĥ 62 and Ĥ 18 2 respectively. The OFDM symbol received at time t 3 is decoded for estimation of the channel responses of the pilot sub-channels C( 0 ) and C( 9 ). The 0 th and 9 th blocks of the memory are updated by replacing the previously stored values (Ĥ 02 and 1) with the newly estimated channel responses Ĥ 03 and Ĥ 93 respectively. The values stored in the blocks for the other non-pilot sub-channels (through which no pilot symbol is transmitted) remain unchanged (the initial value of 1). [0026] In step 303 , the memory is updated according to the second received group of OFDM symbols. More specifically, the OFDM symbol received at time t 4 is decoded for estimation of the channel responses of the pilot sub-channels C( 0 ) and C( 12 ). The 0 th and 12 th blocks of the memory are updated by replacing the previously stored values (Ĥ 03 and Ĥ 12 0 ) with the average of Ĥ 03 and Ĥ 04 , and the average of Ĥ 12 0 and Ĥ 12 4 respectively. The OFDM symbol received at time t 5 is decoded for estimation of the channel responses of the pilot sub-channels C( 0 ), C( 3 ) and C( 15 ). The 0 th , 3 rd and 15 th blocks of the memory are updated by replacing the previously stored values with the average of ½(Ĥ 03 +Ĥ 04 ) and Ĥ 05 , the average of Ĥ 31 and Ĥ 35 , and the average of Ĥ 15 1 and Ĥ 15 5 respectively. The operations for time t 6 and t 7 are similar to those for time t 4 and t 5 . [0027] In step 305 , channel responses of the non-pilot sub-channels are derived by frequency-domain interpolation of the estimated channel responses of the pilot sub-channels. The blocks corresponding to the non-pilot sub-channels are updated by replacing the initial values with the newly derived channel responses. [0028] Finally, frequency equalization is performed on the received signal Y ki using the channel responses obtained by the previously described steps. [0029] Although only the first two received groups of OFDM symbols are included in the previously described embodiment, the present invention are not limited thereto and three or more groups may be included. The more groups are included for the estimation, the less the noise influences the result. Referring to the equations (1) and (2), the difference between the channel response estimated using the pilot symbols and the actual channel response is denoted by: [0000] Δ H=H ki −Ĥ ki =N ki /X ki   (3) [0030] The noise N can be considered to be Gaussian noise with an average value equal to 0. Thus, the value of ΣΔH converges to 0 as the number of times the step 303 is repeated increases. [0031] In the previously described embodiment, only the time-independent channel responses of different sub-channels are stored due to insignificance of time-dependent variation of the channels. Thus, the operation of estimation is simplified and only a small amount of memory and resources are required. [0032] While the invention has been described by way of example and in terms of a preferred embodiment, it is to be understood that the invention is not limited thereto. On the contrary, it is intended to cover various modifications and similar arrangements and procedures, and the scope of the appended claims therefore should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements and procedures.
A method of channel estimation is provided. The method is applied to a communication system having signals transmitted via a plurality of pilot and non-pilot sub-channels. The method comprises the steps of obtaining a first and second channel responses of each pilot sub-channel using pilot symbols received during a first and second time duration respectively, obtaining an estimated channel response of each pilot sub-channel by averaging the first and second channel responses thereof, and obtaining an estimated channel response of each non-pilot sub-channel by interpolation of those of the pilot sub-channels.
7
This is a continuation of application Ser. No. 483,098, filed Apr. 8, 1983 abandoned. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is directed to a coating attachment for a wire weaver. Specifically the present invention is an assembly for dabbing a protective coating such as paint on the ends of chain link formed by the wire weaver. 2. Description of the Prior Art In the manufacture of chain link for fencing, individual wire from rolls is coiled and the coils are woven together and then cut to form the chain link. Although the wire may be galvanized or plastic coated, the cut ends are exposed and can rust and deteriorate after such exposure to the elements. It is desirable therefore, to coat the cut ends of the chain link with paint or other protective material. In the prior art, attempts have been made to coat the ends of the chain link but generally these attempts have involved a cumbersome hand operation. For example, an operator may actually use a paint brush to dab the ends with paint or may use a spray to spray the ends. The use of such hand operations is highly labor intensive and the results are inconsistent. Moreover, the use of a paint brush or spray does not insure that a sufficiently thick enough coating of paint or other protective material is applied to the cut ends. SUMMARY OF THE INVENTION The present invention is directed to an assembly which is attached to an automatic chain link weaving machine which provides for dabbing the cut ends of the chain link with a plate member coated with a liquid substance such as paint, so as to transfer a sufficient quantity of paint to the cut ends to coat and seal the cut ends of the chain link. The plate member is actuated from a supply position, where the plate member receives a quantity of paint, to an operating position in contact with the ends of the chain link, and with the plate member universally adaptable in position to adjust to variations in the cut ends of the chain link to insure that the cut ends always receive a sufficient quantity of paint. In particular, the paint dabbing assembly is driven by a drive portion of the chain link weaver to insure that the paint dabbing assembly is in sychronism with the chain link drive. Specifically, a cam structure may be coupled to a take up drive, and with the cam structure actuating a number of pivoted arms so as to operate a paint dabbing plate from the supply position, to receive the paint, to the operative position to apply the paint to the cut ends of the chain link. The pivoted arms produce the desired motion of the paint dabbing plate and the paint dabbing plate is mounted with an universal type joint to compensate for any irregularities in the cut ends of the chain link. BRIEF DESCRIPTION OF THE DRAWINGS A clearer understanding of the invention will be had with reference to the following description and drawings wherein: FIG. 1 illustrates an automatic wire weaver for producing chain link and incorporating a dabber assembly of the present invention at a position intermediate a weaving position and a turret position; FIG. 2 illustrates in detail a side view of the dabber assembly of the present invention and with the dabber plate positioned to receive a fresh supply of coating material; FIG. 3 illustrates a side view of the dabber assembly of the present invention and with the dabber plate in the contact position to apply the coating material to the cut ends of the chain link; FIG. 4 illustrates a portion of a chain link showing cut ends coated with the protective material and either having barbed ends or knuckled ends; FIG. 5 illustrates a top view of the dabber assembly of the present invention and with the dabber plate at the contact position; FIG. 6 illustrates a perspective view of the dabber assembly of the present invention and with the dabber plate at the contact position; FIG. 7 is an enlarged detailed view of the dabber plate and holder and showing the universal movement of the dabber plate to adjust for differences in the cut ends of the chain link. DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows an automatic wire weaver 10 for the production of chain link and incorporating paint dabber assemblies 12 of the present invention. Two (2) assemblies 12 are shown located on opposite sides of the chain link as it exits the wire weaver. The wire weaver 10 itself may be of an automatic two (2) wire type wherein wire from large coils of wire (not shown) are continuously fed into a coiling mechanism 14 so that two wires at a time are intercoiled and then woven by a weaving mechanism 16 to form continuous lengths of chain link 18. After weaving the wire is cut by cutter means 17 so that opposite ends 20 of the chain link 18 are freshly cut. The chain link 18 may be made of material such as galvanized material or plastic coated material which is generally resistant to weather. However, the freshly cut ends 20 are not protected and could become rusted and deteriorate when subject to the weather over a period of time. The present invention provides for the paint dabber assembly 12 to dab the cut ends 20 of the chain link 18 with a protective coating, such as a protective paint, to seal the cut ends 20 and prevent the cut ends from rusting and weathering. The chain link 18 as it exits from the wire weaving machine 10 generally passes over rollers 22 and 24. The chain link is held in a stretched out position as it passes over the rollers 22 and 24. The paint dabber assembly 12 is located intermediate the rolls 22 and 24 to coat the cut ends 20 of the stretched chain link 18. Subsequent to coating the ends 20 it is usually desirable to further modify the ends by turrets such as by knuckling the ends over. The knuckling may be accomplished by the use of turret knucklers 26 to produce a knuckled end 28 for the chain link fence as shown in FIGS. 3 and 4. As an alternative, the ends may be barbed by barbing turrets which further twist the ends 20 to lock the ends together and have the sharply cut ends protrude outwardly as shown in FIG. 4. The use of such barbing or knuckling turrets are common and any standard type of barbing or knuckling turrets may be used with the present invention. As the chain link 18 is formed by the coiling, weaving and cutting mechanisms 14, 16 and 17, the formation occurs in increments since each pair of wires are woven while the completed chain link 18 remains stationary. Once each pair of wires is woven onto the end of the chain link 18, the completed chain link is moved incrementally over the guide rollers 22 and 24 by a take-up unit (shown in FIG. 2) to position the chain link to receive the next pair of wires for weaving. Typically the barbing or knuckling of the ends 20 occur with the chain link 18 in its stationary position. In a similar fashion, the paint dabber assembly 12 provides for the cut ends 20 to be coated while the chain link 18 is in the stationary position. The take-up unit is driven intermittently to provide for the desired incremental movement of the chain link 18 and therefore the paint dabbing assembly 12 as well as other auxiliary assemblies such as the barbing or knuckling attachments may be all driven in accordance with the intermittent movement of the take-up unit. In particular, the paint dabbing assembly 12 may be driven directly off a chain drive 30 which chain drive may be driven by the take-up unit. This is shown in FIG. 2, where the chain 30 is coupled to a shaft 29 driven at one end by a motor 31. Mounted along the shaft 29 are a plurality of cogs 33 which extend along the width of the chain link 18. The motor 31 intermittenly rotates the shaft 29 to provide take-up in synchronism with the wire weaving. A cam 32 having an outer cam surface 34 is directly coupled to the chain drive 30. The cam profile 34 has essentially two (2) extreme levels so that a roller 36 will follow the cam profile 34 between these two (2) levels. This can be seen clearly in FIGS. 2, 3 and 5. The roller 36 is attached to an arm member 38 and with the roller 36 freely rotating to follow the cam profile 34 while at the same time forcing the arm member 38 to also follow the cam profile 34. The arm member is pivoted around a pivot point 40 which pivot point is attached to a fixed surface 42. As can be seen in FIGS. 2 and 3, the arm member 38 pivots around the pivot point 40 as the roller 36 follows the cam profile 34. Extending from the arm member 38 is an adjustable arm member 44. The arm member 44 is attached to the arm member 38 but allows for a small pivoting adjustment since the arm member 44 may pivot slightly around attachment point 46. Once adjusted the arm 44 is locked in position through the use of a locking means 48 passing through a slot 50. Specifically, the locking means 48 may be a bolt which passes through the slot 50 into a threaded opening in the arm member 38 so that the arm member 44 may be pivoted around the pivot point 46 to a desired position and then locked in this position by tightening down the bolt 48. At the end of the adjustable arm 44, a pivot arm 52 is attached to extend substantially perpendicular to the arm 44 and with the pivot arm 52 attached to a follower arm 54. The follower arm 54 is more clearly shown in FIGS. 5 and 6. One end of the follower arm 54 is pivotally attached to the pivot arm 52 while the other end of the follower arm 54 is fixed to an outside portion of a shaft 56. This is clearly shown in FIGS. 5 and 6, where the shaft 56 is shown to extend across a box structure 58 and held for rotation by bearings 60 and 62. The shaft 56 therefore rotates as the follower arm 54 rotates and with the follower arm 54 rotated by movement of the pivot arm 54 and the arm members 38 and 44. The movement of the arm members 38 and 44 is in turn controlled by the roller 36 following the cam profile 34 as the cam 32 is rotated by the chain drive 30. A lifting lever 64 is fixedly attached to the shaft 56 so as to rotate in accordance with the rotation of the shaft 56. Extending from and pivotably attached to the lifting lever 64 is a long arm 66. The lifting lever 64 and long arm 66 are pivotably attached at point 68. An extension spring 70 is connected between the long arm 66 and the shaft 56 so as to tend to pull the long arm 66 toward the shaft 56. A guide arm 72 extends from a fixed pivot point 74 to a pivot point 76 along the length of the long arm 66. The guide arm 72 pivots around the fixed pivot point 74 as the paint dabbing assembly 12 is moved between the positions shown in FIGS. 2 and 3. In particular, as shown in FIG. 3, the guide arm 72 has a substantially upright position whereas in FIG. 2 the guide arm 72 has been rotated away from the upright position and towards a horizontal position. This causes the free end of the long arm 66 to be thrust up and out as the paint dabber assembly 12 is moved from the position shown in FIG. 2 to the position shown in FIG. 3. This movement of the free end of the long arm 66 is in accordance with the cam roller 36 following the profile 34 of the cam 32. At the free end of the long arm 66, a main arm 78 is supported which main arm is formed of two (2) elements coupled together by a locking bolt 80. The angular relationship between the two (2) elements of the main arm 78 may be adjusted and then retained in the adjusted position by tightening the bolt 80. One end of the main arm 80 is attached to the free end of the long arm 66 at position 82. A post 84 extends from the main arm 78 at the other end of the main arm. A dabber plate 86 is mounted to the post 34 of the end of the main arm 78 to allow for universal movement of the dabber plate so as to insure the proper transfer of coating material, such as paint, to the ends 20 of the chain link 18. In particular, the dabber plate 86 includes a slotted keeper 88 which extends backwardly from the dabber plate to have the slot portion of the keeper extend around the main arm 78. The keeper allows movement of the dabber plate relative to the main arm 78 but prevents rotation of the dabber plate around the main arm 78. The dabber plate 86 is attached to the post 84 by a screw member 90 which passes through an opening 92 in the dabber plate 86 and with the screw member received within a threaded opening in the post 84. The screw member 90 has an enlarged head but with the shaft portion of the screw member smaller than the opening 92. This insures that the dabber plate 86 may rock universally in any direction, as shown by the arrows in FIGS. 5 and 7, but with the slotted portion of the keeper 88 preventing rotation of the dabber plate relative to the arm 78. In order to keep the dabber plate 86 in a generally upright position while contacting the ends 20 of the chain link 18, a compression spring 94 fits over the post 84 and extends between the back of the dabber plate 86 and the end of the arm 78 and pushes against the back of the dabber plate 86. The spring compression, of course, may be overcome as the surface of the dabber plate 86 contacts the ends 20 of the chain link 18 so that the dabber plate 86 may assume a proper contact position with the ends 20 such as shown in FIG. 3. The paint dabber assembly 12 includes a tray 96 containing a supply of coating material such as paint 98. In the position shown in FIG. 2, the dabber plate 86 is submerged in the coating material 98. In this position, the dabber plate receives a fresh supply of coating material. As the dabber plate is lifted upward and outward from the position shown in FIG. 2 to the position shown in FIG. 3, any excess coating material will fall downwardly into the tray 96. The position of the dabber plate just prior to contact with the ends 20 is shown in the dotted position in FIG. 2. At the time of contact the dabber plate is pushed against the ends 20 and any irregularity in the ends 20 or between the ends 20 is compensated since the dabber plate will universally rock as shown in FIGS. 5 and 7 so as to provide the proper contact with the ends 20. A portion of the coating material on the surface of the dabber plate is now transferred to the ends 20. The dabber plate 86 contains a sufficient quantity of coating material 98 so as to insure a proper transfer of the coating material to completely cover the cut portions of the ends 20. The coated ends are shown at position 100. As a further step after coating, the ends 20 may be knuckled to produce the knuckled ends 28 shown in FIG. 3. Alternatively, the ends 20 may be further twisted so as to produce a barbed end 27 as shown in FIG. 4. In addition to the adjustments between the different arm members as described above, the entire paint dabber assembly may be adjusted by a slide mechanism 102 located on the underside of the box 58 and tray 96. In particular, the box and tray may be slid relative to the hold down structure 104 through the use of bolts 106 located in slots 108. The present invention therefore provides for the coating of the cut ends of chain link, and with the coating accomplished using a multi arm structure for translating a rotational caming motion to a linear motion to have the multi arm structure move a dabber plate from a first position, wherein the dabber plate is immersed in a supply of coating material, to a second position where the dabber plate is moved into and against the cut ends of the chain link, so as to transfer the coating material to the cut ends and with the dabber plate having universal rocking motion to accommodate irregularities in the cut ends. The dabber plate assembly of the present invention provides for the movement of the dabber plate using positive pivoted arms directly driven by a cam action so as to insure that the same motion occurs each time so that each pair of cut ends is properly coated with protective material. Although the invention has been described with reference to a particular embodiment it should be appreciated that various adaptations and modifications may be made and the invention is only to be limited by the appended claims.
A coating attachment for a wire weaver for dabbing cut ends of chain link formed by the wire weaver with a protective coating, including mounting the coating attachment at a position adjacent cut ends of chain link after the forming of the chain link by the wire weaver, and with the coating attachment including a receptacle containing a supply of the protective coating, a dabber member for transferring the protective coating from the receptacle to cut ends of chain link, moving the dabber member between a first position within the receptacle for transferring coating material to the dabber member and a second position in contact with the cut ends for transferring coating material from the dabber member to the cut ends, and driving the dabber member in synchronism with the forming of the chain link by the wire weaver.
1
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates generally to chemical mechanical polishing (CMP) systems and techniques for improving the performance and effectiveness of CMP operations. Specifically, the present invention relates to a substrate carrier having an active sacrificial retaining ring. 2. Description of the Related Art In the fabrication of semiconductor devices, there is a need to perform CMP operations, including polishing, buffing and wafer cleaning. Typically, integrated circuit devices are in the form of multi-level structures. At the substrate level, transistor devices having diffusion regions are formed. In subsequent levels, interconnect metallization lines are patterned and electrically connected to the transistor devices to define the desired functional device. As is well known, patterned conductive layers are insulated from other conductive layers by dielectric materials, such as silicon dioxide. At each metallization level and/or associated dielectric layer, there is a need to planarize the metal and/or dielectric material. Without planarization, fabrication of additional metallization layers becomes substantially more difficult due to the higher variations in the surface topography. In other applications, metallization line patterns are formed in the dielectric material, and then metal CMP operations are performed to remove excess metallization. In the prior art, CMP systems typically implement belt, orbital, or brush stations in which belts, pads, or brushes are used to polish, buff, and scrub one or both sides of a wafer. Slurry is used to facilitate and enhance the CMP operation. Slurry is most usually introduced onto a moving preparation surface, e.g., belt, pad, brush, and the like, and distributed over the preparation surface as well as the surface of the semiconductor wafer being buffed, polished, or otherwise prepared by the CMP process. The distribution is generally accomplished by a combination of the movement of the preparation surface, the movement of the semiconductor wafer and the friction created between the semiconductor wafer and the preparation surface. In a typical CMP system, a wafer is mounted on a carrier, which rotates in a direction of rotation. The CMP process is achieved when the exposed surface of the rotating wafer is applied with force against a polishing pad, which moves or rotates in a polishing pad direction. Some CMP processes require that a significant force be used at the time the rotating wafer is being polished by the polishing pad. Normally, the polishing pads used in the CMP systems are composed of porous or fibrous materials. Depending on the type of the polishing pad used, slurry composed of an aqueous solution containing different types of dispersed abrasive particles such as SiO 2 and/or Al 2 O 3 may be applied to the polishing pad, thereby creating an abrasive chemical solution between the polishing pad and the wafer. FIG. 1A depicts a cross-sectional view of an exemplary prior art CMP system. The CMP system of FIG. 1A depicts a carrier head 100 engaging a wafer 102 utilizing a retaining ring 101 . The carrier head 100 is applied against the polishing pad surface 103 a of a polishing pad 103 with a force F. As shown, the top surface of the retaining ring 101 is positioned above the front surface of the wafer 102 . Thus, while the front surface of the wafer 102 is in contact with the polishing pad surface 103 a , the surface of the retaining ring 101 is configured not to come into contact with the polishing pad surface 103 a. Several problems may be encountered while using a typical prior art CMP system. One recurring problem is called “edge-effect” caused by the CMP system polishing the edge of the wafer 102 at a different rate than other regions, thereby creating a non-uniform profile on the surface of the wafer 102 . The problems associated with edge-effect can be divided into two distinct categories of the “pad rebound effect” and “edge burn-off effect.” FIG. 1B is an enlarged illustration of the pad rebound effect associated with the prior art. The pad rebound effect occurs when the polishing pad surface 103 a initially comes into contact with the edge of the wafer 102 causing the polishing pad surface 103 to bounce off the wafer 102 . As the moving polishing pad surface 103 a shifts under the surface of the wafer 102 , the edge of the wafer 102 cuts into the polishing pad 103 at the edge contact zone 104 c , causing the polishing pad 103 a to bounce off the wafer 102 , thereby creating a wave on the polishing pad 103 . Ideally, the polishing pad 103 is configured to be applied to the wafer 102 at a specific uniform pressure. However, the waves created on the polishing pad 103 create a series of low-pressure regions such as an edge non-contact zone 104 a and a non-contact zone 104 a , wherein the removal rate is lower than the average removal rate. Thus, the regions of the wafer 102 which came into contact with the polishing pad surface 103 a such as the edge contact zone 104 c and a contact zone 104 b , are polished more than the other regions. As a result, the CMP processed wafer will tend to show a non-uniform profile. Further illustrated in FIG. 1B is the edge “burn-off.” As the polishing pad surface 103 a comes into contact with the sharper edge of the wafer 102 at the edge contact zone 104 c , the edge of the wafer 102 cuts into the polishing pad 103 , thereby creating an area defined as a “hot spot,” wherein the pressure exerted by the polishing pad 103 is higher than the average polishing pressure. Thus, the polishing pad surface 103 a excessively polishes the edge of the wafer 102 and the area around the edge contact zone 104 (i.e., the hot spots). The excessive polishing of the edge of the wafer 102 occurs because a considerable amount of pressure is exerted on the edge of the wafer 102 as a result of the polishing pad surface 103 a applying pressure on a small contact area defined as the edge contact zone 104 c . As a consequence of the burn-off effect, a substantially high removal rate is exhibited at the area within about 1 millimeter to about 3 millimeters of the edge of the wafer 102 . Moreover, depending on the polisher and the hardware construction, a substantially low removal rate is detected within the edge non-contact zone 104 a ′, an area between about 3 millimeters to about 20 millimeters of the edge of the wafer 102 . Accordingly, as a cumulative result of the edge-effects, an area of about 1 millimeter to about 20 millimeters of the edge of the resulting post CMP wafers sometimes could be rendered unusable, thereby wasting silicon device area. Although, occasionally, an air bearing has been implemented in an attempt to compensate for the different levels of pressure applied by the polishing pad 103 , air bearings have almost never been able to completely compensate for the difference in the pressure levels. Particularly, at the edge contact zone 104 c , the edge non-contact zone 104 a ′, the contact zone 104 b , and the non-contact zone 104 a the use of air bearings do not completely compensate for the difference in the exerted pressure, as the air can easily escape. A common problem associated with the pad rebound effect and the edge burn off effect is the non-uniformity of the wafer 102 caused by the lack of uniform distribution of slurry between the polishing pad surface 103 a and the surface of the wafer 102 . As the edge of the wafer 102 cuts into the polishing pad surface 103 a , it causes the slurry to be squeezed out of the polishing pad 103 , thereby preventing the polishing pad surface 103 a from performing a thorough polishing operation on the edge of the wafer 102 . Thus, to accomplish a proper polishing operation, additional slurry must be supplied to the polishing interface. Consequently, a significant amount of slurry is wasted as a result of the combined effects of the pad rebound effect and edge burn-off effect. In view of the foregoing, a need therefore exists in the art for a chemical mechanical polishing system that substantially eliminates damaging edge-effects and their associated removal rate non-uniformities while efficiently facilitates slurry distribution. SUMMARY OF THE INVENTION Broadly speaking, the present invention fills these needs by providing a system, which yields a substantially uniform removal rate throughout the surface of a wafer. In a preferred embodiment, the CMP system is designed to implement an active retaining ring configured to have a sacrificial component, which simulates the pattern of the substrate being polished by utilizing a plurality of collimated holes. As the sacrificial component is being polished together with the wafer, the edge of the polishing interface is thus virtually extended to the outside of the substrate being polished, thereby eliminating the aforementioned edge-effects, pad rebound effects, and edge bum-off effects. It should be appreciated that the present invention can be implemented in numerous ways, including as a process, an apparatus, a system, a device, or a method. Several inventive embodiments of the present invention are described below. In one embodiment, a retaining ring structure of a carrier head for use in a chemical mechanical polishing system (CMP) is disclosed. The retaining ring structure includes a retaining ring support and a sacrificial retaining ring designed to confine a substrate to be polished. The sacrificial retaining ring also has an upper surface and a contact surface. The upper surface of the sacrificial retaining ring is configured to be attached to the retaining ring support, such that the retaining ring support holds the sacrificial retaining ring. The contact surface of the sacrificial retaining ring is configured to be substantially planer with a top surface of the substrate being polished. In another embodiment, a wafer holding and application apparatus for use in chemical mechanical polishing (CMP) applications is disclosed. The apparatus includes a carrier head and a retaining ring support, which is designed to be attached to the carrier head. Also included in the apparatus is a sacrificial retaining ring, which is attached to the retaining ring support. The sacrificial retaining ring is designed to confine a wafer at a desired location when the carrier head applies the wafer to a polishing surface. The retaining ring support is defined from a material that approximates the wafer. A contact surface of the sacrificial retaining ring is positioned approximately planar with a to be polished surface of the wafer. In yet another embodiment, a method for making a carrier head to be used in chemical mechanical polishing (CMP) of a wafer is disclosed. The method includes generating a retaining ring support and attaching the retaining ring support to the carrier head. Also included in the method is generating a plurality of capillary tube array units each having a contact surface. The method further includes attaching each of the plurality of capillary tube array units around the retaining ring support such that the plurality of capillary tube array units define a sacrificial retaining ring designed to contain the wafer having a surface to be polished. In addition, the surface of the wafer to be polished and the contact surface of each of the plurality of capillary tube array units are defined at about a same planar position. The advantages of the present invention are numerous. Primarily, in contrast to prior art CMP systems, the contact surface of the sacrificial retaining ring is positioned substantially on a same horizontal plane as the top surface of the wafer, thereby virtually extending the polishing interface to the outside of the surface of the wafer. As such, the present invention eliminates the negative effects of the edge-effects, pad rebound effects, and edge burn-off effect. In addition, the construction of the sacrificial retaining ring out of plurality of capillary tube array units having plurality of capillary tubes facilitates the uniform distribution of slurry to the polishing interface so as to achieve a substantially uniform material removal through out the surface of the wafer. Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention. BRIEF DESCRIPTION OF THE DRAWINGS The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, and like reference numerals designate like structural elements. FIG. 1A is an illustration of the prior art CMP system. FIG. 1B is an illustration of the pad rebound effect and edge burn-off effect associated with the prior art. FIG. 2 depicts the non-uniform removal rate of materials from a polishing interface, in accordance with one embodiment of the present invention. FIG. 3A is an exploded cross-sectional view of a CMP carrier head engaging a retaining ring support holding a sacrificial retaining ring, in accordance with another embodiment of the present invention. FIG. 3B-1 is an enlarged cross-sectional view of a polishing pad surface being applied to a wafer and a sacrificial retaining ring without introducing additional slurry, in accordance with yet another embodiment of the present invention. FIG. 3B-2 is an enlarged cross-sectional view of a polishing pad surface being applied to a wafer and a sacrificial retaining ring utilizing a slurry guide inlet to supply additional slurry to the sacrificial retaining ring via a slurry distribution manifold, in accordance with yet another embodiment of the present invention. FIG. 4A depicts the structure of a retaining ring and the relative position of a sacrificial retaining ring with respect to the retaining ring support, in accordance with et another embodiment of the present invention. FIG. 4B depicts the relative positions of multiple capillary tube array units with respect to each other as well as a wafer, in accordance with yet another embodiment of the present invention. FIG. 4C is a three-dimensional view of a capillary tube array unit, in accordance with yet another embodiment of the present invention. FIG. 5A depicts the retaining ring support holding the capillary tube array units utilizing a contiguous ring finger, in accordance with yet another embodiment of the present invention. FIG. 5B depicts the sacrificial retaining ring being mounted on the retaining ring support utilizing microscrews, in accordance with yet another embodiment of the present invention. FIG. 5C depicts a sacrificial retaining ring being affixed to a retaining ring support utilizing glue, in accordance with yet another embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An invention for a CMP system, which substantially eliminates the aforementioned edge-effects, pad rebound effects, and edge burn-off effects is disclosed. In preferred embodiments, the CMP system implements an active retaining ring having a sacrificial component, which simulates the patterned surface of the wafer while relocating the line of contact of the polishing pad and the wafer, outside of the wafer surface and onto the outer edge of the sacrificial component of the retaining ring. Preferably, in one implementation, the sacrificial component is constructed from glass (e.g., Silicon dioxide (SiO 2 ), Borosilicate, Soda Lime, etc.) and contains a plurality of capillary tubes, which assist in simulating the patterns on the surface of the wafer and/or facilitate uniform distribution of slurry to the polishing interface. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be understood, however, to one skilled in the art, that the present invention may be practiced without some or all of these details. In other instances, well known process operations have not been described in detail in order not to unnecessarily obscure the present invention. Graph 150 of FIG. 2 depicts the non-uniform removal rate of materials from a polishing interface, in accordance with the present invention. A removal rate axis 152 of the graph 150 illustrates the fluctuation of the removal rates of materials at different points of the polishing area axis 154 . In accordance with one embodiment of the present invention, the CMP system starts the polishing operation at an edge of a sacrificial retaining ring (SRR) 176 so as to achieve a removal rate of 172 . Thereafter, as a result of the edge-effect, pad rebound effect, and burn-off effect, a maximum removal rate 174 is achieved at a point 158 , which corresponds to a point 178 located on the Sacrificial Retaining Ring (SRR) 201 a . Then, the graph descends, depicting a point 160 , which corresponds to the CMP machine polishing a point 180 located on the SRR 201 a having a removal rate of 168 . Subsequently, a substantially lower removal rate of 166 is achieved for the point 182 positioned within the bounce back region of the polishing area axis 154 still located within the SRR 201 a corresponding to a point 162 of the graph. Then, at a point 164 of the graph, a substantially uniform removal rate of 170 is achieved. As depicted, the point 164 corresponds to a position 184 of the polishing area axis, representing approximately the end of the SRR 201 a and approximately the beginning of the true edge of a wafer 202 . Thus, as illustrated, the non-uniform removal rate caused by the edge-effect, pad rebound effect, and edge burn-off effect has been substantially eliminated by virtually extending the edge of the polishing interface to outside of the wafer 202 . FIG. 3A is an exploded cross-sectional view of a CMP carrier head 200 engaging a retaining ring support (RRS) 201 b holding a sacrificial retaining ring (SRR) 201 a . Also shown are a plurality of vacuums 206 feed through in a carrier film 204 engaging a wafer 202 . The surface of the carrier film 204 may include approximately about 4 to 12 vacuum holes 206 . The vacuums 206 are configured to retain the wafer 202 via carrier film 204 , when the carrier head 200 is no longer in contact with the surface of the polishing pad 103 a . As depicted, the top surface of the wafer 202 as well as the contact surface of the SRR 201 a are being applied to a polishing pad surface 203 a of a polishing pad 203 . Specifically shown is the planer relationship of the top surface of the wafer 202 and the contact surface of the SRR 201 a , revealing the active sacrificial characteristic of the SRR 201 a. In one preferred implementation, the SRR 201 a is constructed from materials having similar characteristics to those of the material of the substrate being polished. Thus, in this embodiment, as it is the silicon wafer 202 that is being polished, the SRR 201 a is constructed from a material having similar characteristics as silicon (Si) or the films that are typically present on the surface of the wafer 202 (i.e., glass, dielectrics, metals, etc.). More specifically, the chosen material is preferred to be of a material, which friction with the polishing pad surface 203 a does not introduce any additional defects or contamination to the polishing interface of the SRR 201 a and the wafer 202 . Accordingly, the concurrent polishing of the glass SRR 201 a and the wafer 202 relocates the line of contact of the polishing interface and the polishing pad surface 203 a outside of the wafer 202 and to the edge of the glass SRR 201 a so as to eliminate the aforementioned shortcomings of edge-effects, edge burn-off effects, and pad rebound effects. FIG. 3B-1 is an enlarged cross-sectional view of a polishing pad surface 203 a being applied to a top surface of a wafer 202 and a top surface of a sacrificial retaining ring (SRR) 201 a without introducing slurry through capillary tubes 208 of capillary tube array units 201 a 40 (e.g., through collimated hole structures). As depicted, the top surface of the wafer 202 and the contact surface of the sacrificial retaining ring 201 a are positioned substantially on a same horizontal plane so that the sacrificial retaining ring 201 a can be polished together with the wafer 202 . As shown, the SRR 201 a contains a plurality of capillary tubes 208 , which in this embodiment, extend from the contact surface of the SRR 201 a to a bottom surface of the SRR 201 a . The capillary tubes 208 are configured to simulate the pattern of the surface of the substrate being polished (i.e., the wafer 202 ). Preferably, the diameters of the capillary tubes 208 may vary so as to simulate different types of patterned surfaces of the wafer 202 or different processes so that optimum polishing performance can be achieved. In the embodiment of FIG. 3B-2 slurry is supplied to a slurry distribution manifold 210 through a slurry guide inlet 212 and is subsequently provided to a sacrificial retaining ring 201 a . It must be appreciated that although in this embodiment only one slurry guide inlet 212 is depicted, any number of slurry guide inlets 212 may be utilized to introduce slurry to the CMP system. Furthermore, the slurry guide inlets 212 may be made from any material and be in any shape or form (i.e., tubes, channels, etc.). In one implementation, initially, slurry is supplied to the slurry distribution manifold 210 via a slurry guide inlet 212 . Thereafter, slurry distribution manifold 210 provides slurry to the capillary tubes 208 substantially evenly, which in turn, guide slurry to the polishing interface. As a result, slurry usage is minimized by uniformly injecting sufficient quantity of slurry into the polishing pad surface 203 a at the point of use. Consequently, the polishing pad surface 203 a is saturated with slurry. Thus, as the polishing pad surface 203 a moves across the wafer 202 , sufficient quantity of slurry will be present at the edge of the wafer 202 , the center of the wafer 202 , and the low-pressure regions. The significance of the capillary tubes 208 in facilitating the saturation of the polishing pad 203 with slurry becomes apparent at the instances when the polishing pad surface 203 a is polishing the center of the wafer 202 . Conventionally, due to insufficient presence of slurry at the center of the wafer 202 , the removal rate of materials may decrease as the polishing pad surface 203 a moves away from the edge of the wafer 202 and approaches the center of the wafer 202 . However, in this embodiment, the SRR 201 a saturates the polishing pad surface 203 a by uniformly distributing slurry to the polishing pad surface 203 a . As such, while the surface of the polishing pad 203 a approaches the center of the wafer 202 , the polishing pad surface 203 a contains substantially sufficient quantity of slurry so that the removal rate remains substantially flat from the edge of the wafer 202 to the center of the wafer 202 . The structure of a retaining ring 201 and the relative position of a sacrificial retaining ring 201 a with respect to the retaining ring support 201 b is shown in FIG. 4 A. As depicted, the retaining ring support 201 b is a contiguous ring which diameter is substantially equivalent to the diameter of the wafer 202 . In one embodiment, the retaining ring support 201 b can be constructed from metal (i.e., Stainless Steal, Aluminum, or any other kind of alloy) or plastic. The retaining ring support 201 b is configured to support the sacrificial retaining ring 201 a , which consists of a plurality of capillary tube array units 201 a ′. Although in this embodiment, the sacrificial retaining ring 201 a is configured to be constructed from a plurality of capillary tube array units 201 a ′, it should be appreciated that similar to the retaining ring support 201 b , the sacrificial retaining ring 201 a may be a contiguous ring. However, in this embodiment, in an attempt to simplify manufacturability, a plurality of capillary tube array units 201 a ′ have been utilized. Exemplary structures, such as capillary tube array units 201 a ′, can be custom ordered from Collimated Holes, Inc., of Campbell, Calif. In one preferred implementation, the capillary tube array units 201 a ′ are configured to be placed on top of the retaining ring support 201 b . The capillary tube array units 201 a ′ are placed on top of the RRS 201 b and adjacent to one another so as to ideally create a ring substantially in the size of the wafer 202 . The capillary tube array units 201 a ′ may be placed adjacent to one another in a manner so as to create an empty slot 214 . Alternatively, the capillary tube array units 201 a ′ may be placed next to one another so that no space exists between the two adjacent capillary tube array units 201 a ′. In a preferred embodiment, each capillary tube array unit 201 a ′ contains a plurality of capillary tubes 208 and is constructed from a material which has similar characteristic to those of the wafer 202 (i.e., Silicon) or the films typically present on the wafer 202 . Most importantly, the capillary tube array units 201 a ′ should preferably be constructed from a material that will not contaminate or introduce additional defects to the surface of the post-CMP wafer 202 . Thus, the capillary tube array units containing capillary tubes 208 are configured to simulate the patterned surface of the wafer 202 so as to extend the negative effects of the edge effects, edge burn-off effects, and pad rebound effects out of the surface of the wafer 202 , thereby achieving a less than a 3-millimeter wafer edge exclusion. The three-dimensional FIG. 4B depicts the relative positions of multiple capillary tube array units 201 a ′ with respect to each other as well as a wafer 202 . In this embodiment, the capillary tube array units 201 a ′ are configured to be placed adjacent to each other in a manner so as to leave an empty space defined as a slot 214 . In a preferred implementation, slurry can be supplied to the polishing interface via the capillary tubes 208 as well as the slots 214 thus ensuring the presence of sufficient uniform quantity of slurry through out the surface of the wafer 202 . The three-dimensional view of a capillary tube array unit 201 a ′ is depicted in FIG. 4 C. As shown, a capillary array unit length 201 a′ L of the capillary tube array unit 201 a ′ is configured to have an approximate linear range of about 4 millimeters to about 37 millimeters, and a preferred linear length of about 12 millimeters. Similarly, a capillary tube array unit width 201 a ′ w of the capillary tube array unit 201 a ′ is configured to have an approximate range of about 4 millimeters to about 37 millimeters, and a preferred width of about 12 millimeters. As illustrated, the capillary tubes 208 (e.g., holes) cover about fifty percent (50%) of a top surface of a capillary tube array unit 201 a ′. The approximate capillary tube diameter 208 a of the capillary tube 208 ranges from about 10 micrometers to about 200 micrometers. The preferred inside diameter of the capillary tube 208 is preferably 50 micrometers. Likewise, a capillary tube height 208 b approximately ranges millimeters, and a preferred capillary tube height 208 b of about 6 millimeters. However, it should be appreciated that the diameter size and the height of the capillary tube 208 may vary depending on each particular process so that optimum polishing operation is achieved. FIG. 5A is an illustration of one of several different mounting methods that can be used to place the sacrificial retaining ring 201 a on the retaining ring support 201 b . As shown, the retaining ring support 201 b secures all the individual capillary tube array units 201 a ′ together utilizing a contiguous ring finger 216 . In the embodiment of FIG. 5B, a sacrificial retaining ring 201 a is held down to a retaining ring support 201 b utilizing a fastener (e.g., a microscrews). Alternatively, in a different implementation, as depicted in FIG. 5C, a sacrificial retaining ring 201 a is affixed to a retaining ring support 201 b utilizing an adhesive substance (e.g., Epoxy glue). Although the foregoing invention has been described in some detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. For instance, the embodiments are applicable to any substrate, such as, storage media disks, semiconductor wafers (e.g., 200 mm wafers, 300 mm wafers, etc.), and any other type of substrate requiring polishing, planarization, buffing, or other suitable preparation operations. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalents of the appended claims.
A retaining ring structure of a carrier head designed for use in a chemical mechanical polishing system (CMP) is provided. The retaining ring includes a retaining ring support and a sacrificial retaining ring, which is designed to confine a substrate to be polished. The included sacrificial retaining ring has an upper surface and a contact surface. The upper surface of the sacrificial retaining ring is configured to be attached to the retaining ring support, such that the retaining ring support holds the sacrificial retaining ring. Preferably, the contact surface of the sacrificial retaining ring is configured to be substantially planer with a top surface of the substrate being polished. In a preferred example, the sacrificial retaining ring can include a plurality of capillary tubes and is constructed from a material having substantially the same characteristics as the surface of the substrate to be polished.
1
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention generally relates to solar cells, and more particularly to a light concentrator designed to collect the light that would normally be reflected or fall on the front electrode grid lines and redirect it into the solar cell to thereby increase the efficiency of the cell. 2. Description of the Prior Art: Conventional solar cells have a top surface which is partially covered by thin grid lines. These grid lines as a whole comprise the top or front electrode of the solar cell. At a minimum, the grid lines are arranged to cover only 6% of the surface, but even with that small coverage, they will block 6% of the light from entering into the solar cell and becoming useful, i.e. being converted into electrical current. If a light concentrator were designed to collect the light that would normally fall on the grid lines and redirect it into the cell, at least a 6% increase in the output of the solar cell could be attained. Conventional solar cell coverslides have flat, smooth, surfaces with an antireflection coating on top. In spite of this antireflecting layer, about 3% of the useful light is lost to the cell by reflection from the coverslide. The light concentrator design can be chosen so as to reduce this reflection loss to almost zero. The net increase of the light concentrator on a solar cell would therefore be at least 9% and more likely close to 12%. SUMMARY OF THE INVENTION The present invention solves the problem of light blocked by the grid lines on the surface of a solar cell by providing a lens arrangement which is placed above or directly on top of the solar cell. The lens arrangement takes the form of a plurality of converging lenses which concentrate the light. In one embodiment, a plurality of hemi-cylinders are used, while in another embodiment the cover slide is grooved to form a plurality of sawtooth ridges. Modifications of each of these embodiments include a "waffle" lens where each lens element is generally hemispherical in shape but generated from a square base, and a pyrimidal surface created by two sets of perpendicular grooves. The light concentrator according to the invention increases the output of the solar cell in a number of ways. First, all of the incident light is directed into the solar cell, rather than reflected from the grids or coverslide front surface. Second, with the use of the light concentrator, more grids could be used, reducing surface resistance so that the increased current from the more intense light would not introduce greater power loss than normally encountered. Moreover, the grids could be wider to increase their conductivity. Third, the increased light injection level improves the open circuit voltage and the "fill factor" if the solar cell junction is not ideal. Fourth, in the "waffle" lens and pyrimidal lens modifications, cross-connecting grids can be employed to thereby increase reliability and decrease the distance carriers have to travel in the surface region. BRIEF DESCRIPTION OF THE DRAWING The specific nature of the invention, as well as other objects, aspects, uses and advantages thereof, will clearly appear from the following description and from the accompanying drawing, in which: FIG. 1 is a cross-sectional view showing a first embodiment of the light concentrating solar cell cover according to the invention placed directly on top of a solar cell; and FIG. 2 is a cross-sectional view of a second embodiment of the cover slide according to the invention placed directly on top of a solar cell. DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 illustrates in cross section a conventional solar cell 10 having a plurality of grid lines 11 forming the top electrode on the top surface of the solar cell. The cover slide 12 according to the first embodiment of the invention is in the form of a lens arrangement comprising a plurality of hemi-cylinders. As illustrated in the Figure, the diameter of the hemi-cyclinders is equal to the repeat period of the grid lines 11. The cover slide 12 could be extruded in plastic or glass (for examples) for terrestrial use or formed in fused silica, quartz, or sapphire for space applications. The cover slide may be supported above the solar cell, attached directly to the top surface thereof with a suitable adhesive 13, or integrally bonded directly to the top surface thereof. The hemi-cylinders of the cover slide act as converging lenses which concentrate the incident light 14 on the exposed surface of the solar cell 10 and away form the grid lines 11. An additional advantage of the cover slide structure as illustrated in FIG. 1 is illustrated by the light ray 15. Because of the multiple reflection which occurs between the individual hemi-cylinders, surface reflection is reduced thereby increasing the light transmitted into the solar cell 10. A modification of the hemi-cylinder construction is a "waffle" lens wherein each lensette is generally hemispherical in shape but terminates in a square base rather than a circular base. In the case of a "waffle" lens, FIG. 1 is a cross-sectional view taken along either of two perpendicular directions. An advantage of this lens structure is the greater flexibility in the grid structure permitting cross-connecting of grids to increase reliability and decrease the distance carriers would have to travel in the surface region of the solar cell 10. FIG. 2 shows an alternate construction of the cover slide according to the invention which has the advantage of facilitating the construction of the cover slide. In this embodiment, the cover slide 12' has a grooved surface having a generally sawtooth cross-sectional geometry. The size of the sawtooth would be determined by the number of grid lines 11 with the period between teeth corresponding to the period between the grid lines. Refraction at the surface of the cover slide bends the light on either side of the sawtooth into the center of the sawtooth. If the lowest points of the sawtooth are in registry with the grid lines 11, the grid lines will be shadowed. The shadow will exist under the lowest points of the sawtooth for a whole set of cover slide thickness, but another set exists which will give shadows under the peaks as well. An angle of θ a approximately equal to 45° is the maximum half angle of the apex angle of the sawtooth for assuring that all normally incident light is reflected twice. Decreasing θ a will allow this double reflection of off-normal incident light, which is important for body mounted arrays. The increase in θ 3 , with decreasing θ a does not improve the optical coupling with the standard solar cell. In general, the use of a sawtooth rather than a lens, will reduce the reflection from the surface of the cover and consequently give more light to the surface of the solar cell. However, the light is not as highly concentrated as with a lens and will not increase the injection level to the same extent. A modification of the sawtooth geometry illustrated in FIG. 2 is a square pyrimidal surface produced by a second set of grooves intersecting the first set of grooves at right angles thereto. This modification enjoys the same advantages enumerated for the "waffle" lens above. In the case of the square pyrimidal surface, FIG. 2 is a cross-sectional view taken in either of two perpendicular directions. While the invention has been disclosed in combination with a conventional solar cell illustrated as having a planar or smooth surface, it will be understood by those skilled in the art that solar cells having non-smooth surfaces will also benefit from the use of the light concentrating cover slide of the invention. When non-smooth surface solar cells are considered, the cover slide surface can be optimized for maximum transmission and radiation resistance. It will therefore be apparent that the embodiments shown are only exemplary and that various modifications can be made in construction and arrangement within the scope of the invention as defined in the appended claims.
A cover slide for a solar cell comprises a plurality of converging lenses arranged to focus the incident light so that it does not fall on the grid lines of the front electrode of the solar cell.
7
RELATED CASES This application is a continuation of application Ser. No. 09/111,062 filed Jul. 7, 1998, now abandoned, which is a continuation of application Ser. No. 09/090,598 filed Jun. 4, 1998, now U.S. Pat. No. 5,934,286, which is a continuation of application Ser. No. 09/073,336 filed May 5, 1998, now U.S. Pat. No. 5,979,455, which is a continuation of application Ser. No. 08/702,742 filed Aug. 23, 1996, now U.S. Pat. No. 5,749,375, which is a continuation of application Ser. No. 08/391,960 filed Feb. 21, 1995, now U.S. Pat. No. 5,571,167, which is a continuation of application Ser. No. 08/138,912 filed Oct. 18, 1993, now U.S. Pat. No. 5,456,712, which is a division of application Ser. No. 08/056,371 filed on May 3, 1993, now U.S. Pat. No. 5,304,220, which is a continuation-in-part of application Ser. No. 07/725,597 filed on Jul. 3, 1991, now U.S. Pat. No. 5,211,683. BACKGROUND OF THE INVENTION The present invention relates generally to a method for improving blood flow in the body of a patient and more particularly concerns an extravascular bypass grafting method which utilizes an intravascular approach. Treatment of vascular disease in which the lumen of a blood vessel is significantly narrowed or occluded by atherosclerosis includes surgical and endovascular methods. Conventional surgical methods include obtaining access to a blood vessel via one or more surgical incisions and either removing the blockage by performing an endarterectomy or bypassing the blockage by placing a bypass graft which has a generally cylindrical shape. Endovascular methods include obtaining access to a blood vessel with a catheter and improving blood flow therein by performing an athrectomy, atherolysis, or balloon and laser angioplasty with or without endovascular stent placement. In general, the preferred treatment of severe stenosis or occlusion of a long vessel segment has been surgical bypass grafting. Although conventional surgical bypass grafting is an accepted procedure, it presents substantial morbidity and mortality risks. Also, not all patients are acceptable candidates for the above surgical procedure due to advanced age and preexisting medical conditions. Moreover, conventional surgical bypass grafting is an invasive procedure which may require extended hospitalization due to postoperative recovery. In addition, the above surgical procedure may involve substantial financial costs to patients, hospitals and society in general. Further, incisions made during the above surgical procedure may cause significant cosmetically unattractive scarring which is undesirable to many patients. SUMMARY OF THE INVENTION One embodiment of the present invention involves a method of implanting a graft prosthesis in the body of a patient to bypass a segment of a blood vessel. The method includes the steps of (1) making an incision in the body, (2) positioning a graft so that one end of the graft is located substantially adjacent the blood vessel at a site upstream of the segment and a second end of the graft is located substantially adjacent the blood vessel at a site downstream of the segment, wherein the positioning step includes the step of placing the graft into the body through the incision, and further wherein the positioning step is performed while the upstream site is covered by a substantially intact portion of the epidermis of the body, (3) isolating a region of the area within the blood vessel substantially adjacent the upstream site from fluid communication with the rest of the area within the blood vessel, wherein the upstream isolating step is performed while the upstream site is covered by the substantially intact portion of the epidermis of the body, (4) making an arteriotomy in a sidewall of the blood vessel substantially adjacent the upstream site to create a communicating aperture between the upstream isolated region and an area outside of the blood vessel, wherein the upstream arteriotomy making step is performed while the upstream site is covered by the substantially intact portion of the epidermis of the body, (5) forming an anastomosis between the one end of the graft and the blood vessel substantially adjacent the upstream site, wherein the upstream anastomosis forming step is performed while the upstream site is covered by the substantially intact portion of the epidermis of the body, and further wherein the upstream anastomosis forming step includes the step of suturing the one end of the graft to the blood vessel, (6) isolating a region of the area within the blood vessel substantially adjacent the downstream site from fluid communication with the rest of the area in the blood vessel, (7) making an arteriotomy in the sidewall of the blood vessel substantially adjacent the downstream site to create a communicating aperture between the downstream isolated region and the area outside of the blood vessel, and (8) forming an anastomosis between the second end of the graft and the blood vessel substantially adjacent the downstream site. Another embodiment of the present invention involves a method for implanting an end portion of a graft within the body of a patient during a bypass grafting procedure. The method includes the steps of (1) making an incision in the body at a first location, (2) isolating a region of the area within a blood vessel of the body substantially adjacent a second location from fluid communication with the rest of the area within the blood vessel, wherein the first location is remote from the second location, and further wherein the isolating step is performed while the second location is covered by a substantially intact portion of the epidermis of the body, (3) making an arteriotomy in the sidewall of the blood vessel substantially adjacent the second location to create a communicating aperture between the isolated region and the outside of the blood vessel, wherein the arteriotomy making step is performed while the second location is covered by the substantially intact portion of the epidermis of the body, (4) advancing the end portion of the graft through the incision to the second location, wherein the advancing step is performed while the second location is covered by the substantially intact portion of the epidermis of the body, and (5) forming an anastomosis between the end portion of the graft and the blood vessel substantially adjacent the second location, wherein the anastomosis forming step is performed while the second location is covered by the substantially intact portion of the epidermis of the body, and further wherein the anastomosis forming step includes the step of suturing the end portion of the graft to the blood vessel. Still another embodiment of the present invention involves a graft which is securable to a sidewall of a blood vessel having an arteriotomy defined therein. The graft includes a body portion, and a flanged end portion attached to the body portion, the flanged end portion being positionable substantially adjacent a portion of the sidewall of the blood vessel which substantially surrounds the arteriotomy. Yet another embodiment of the present invention involves a graft and stent assembly which is securable to a sidewall of a blood vessel having an arteriotomy defined therein. The graft and stent assembly includes a graft having an end portion which is positionable within the blood vessel and substantially adjacent a portion of the sidewall of the blood vessel which substantially surrounds the arteriotomy. The graft and stent assembly further includes a stent positionable within the blood vessel and in contact with the end portion of the graft so as to secure the end portion of the graft between the sidewall of the blood vessel and the stent. One object of the present invention is to provide an improved method for implanting a graft prosthesis in the body of a patient. Another object of the present invention is to provide an improved method for implanting an end portion of a graft within the body of a patient. Still another object of the present invention is to provide a method of implanting a graft prosthesis in the body of a patient which is less invasive relative to conventional surgical bypass grafting procedures. Yet another object of the present invention is to provide a method of implanting a graft prosthesis in the body of a patient which obviates at least one surgical incision (e.g. the abdominal surgical incision) as compared to conventional surgical bypass grafting procedures. Still another object of the present invention is to provide a method of implanting a graft prosthesis in the body of a patient which has low morbidity and mortality risk to patients. Yet another object of the present invention is to provide a method of implanting a graft prosthesis in the body of a patient which can be performed on patients whom are elderly or have poor preexisting medical conditions. Still another object of the present invention is to provide a method of implanting a graft prosthesis in the body of a patient which requires relatively less financial costs to patients, hospitals and society in general as compared to conventional surgical bypass grafting techniques. Yet another object of the present invention is to provide an improved graft prosthesis. Still another object of the present invention is to provide an improved graft and stent assembly. Another object of the present invention is to provide a graft which can be conveniently secured to a blood vessel. Yet another object of the present invention is to provide a graft and stent assembly which allows the graft to be conveniently secured to a blood vessel. Yet still another object of the present invention is to provide a graft which is easy to implant in the body of a patient. Still another object of the present invention is to provide a graft and stent assembly which is easy to implant in the body of a patient. Another object of the present invention is to provide a graft which functions well after it is implanted in the body of a patient. Yet another object of the present invention is to provide a graft and stent assembly which functions well after it is implanted in the body of a patient. Other objects and benefits of the present invention can be discerned from the following description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary front elevational view of a human body showing a blood vessel which includes the aorta, the right common iliac artery, the right common femoral artery and the left common femoral artery wherein a segment of the blood vessel is occluded. FIG. 1 also shows a portion of each inguinal ligament of the human body. FIG. 2 is an enlarged fragmentary view of the human body and blood vessel of FIG. 1 . FIG. 3 shows the human body and blood vessel of FIG. 2 with a balloon-tip catheter positioned within the blood vessel wherein the balloon is inflated in accordance with the preferred method of the present invention. FIG. 4 is a view similar to FIG. 3 but showing a second balloon-tip catheter positioned within the blood vessel wherein the second balloon is inflated in accordance with the preferred method of the present invention. FIG. 5 is a view similar to FIG. 4 but showing the blood vessel in phantom except for a portion thereof that is exposed through a gaping surgical incision. Also shown exposed through the surgical incision in FIG. 5 is a portion of the right inguinal ligament. FIG. 6 is a view similar to FIG. 5 but showing another portion of the blood vessel, including the aorta, exposed for clarity of description. Moreover, in FIG. 6, a laparoscope (depicted schematically) is shown inserted through the surgical incision in accordance with the preferred method of the present invention. FIG. 7 is a view similar to FIG. 6 but showing a needle positioned within the laparoscope in accordance with the preferred method of the present invention. FIG. 8 is a view similar to FIG. 7 but showing the needle removed from the laparoscope and replaced with a scissors device in accordance with the preferred method of the present invention. FIG. 9A is an elevational view of a graft prosthesis used in carrying out the preferred method of the present invention. FIG. 9B is a fragmentary sectional view. taken along the line 9 B— 9 B of FIG. 9A as viewed in the direction of the arrows. FIG. 9C is a fragmentary perspective view of the graft prosthesis of FIG. 9A showing its outwardly extending flanged end portion. FIG. 9D is another fragmentary perspective view of the graft prosthesis of FIG. 9A showing its outwardly extending flanged end portion. FIG. 9E is a view similar to FIG. 9C but showing a plurality of springs, in phantom, integrally positioned within the outwardly extending flanged end portion, in addition to, a portion of the sidewalls of the graft prosthesis of FIG. 9 A. FIG. 9F is an elevational view of one of the plurality of springs of FIG. 9 E. FIG. 9G is an elevational view of another of the plurality of springs of FIG. 9 E. FIG. 9H is an elevational view of yet another of the plurality of springs of FIG. 9 E. FIG. 9I is an elevational view of still another of the plurality of springs of FIG. 9 E. FIG. 10A is an elevational view of the graft prosthesis of FIG. 9A wherein the graft prosthesis is in a rolled configuration. FIG. 10B is a cross-sectional view taken along the line 10 B— 10 B of FIG. 10A as viewed in the direction of the arrows. FIG. 11A is an elevational view of the laparoscope of FIG. 6 . Moreover, FIG. 11A shows the graft prosthesis of FIG. 10A, positioned within the laparoscope in accordance with the method of the present invention. FIG. 11A further shows a plunger, used in carrying out the preferred method of the present invention, partially positioned within the laparoscope in accordance with the preferred method of the present invention. FIG. 11B is a cross-sectional view taken along the line 11 B— 11 B of FIG. 11A as viewed in the direction of the arrows. FIG. 12 is a view similar to FIG. 8 but showing the scissors device removed from the laparoscope and replaced with the graft prosthesis and plunger of FIG. 11A in accordance with the preferred method of the present invention. FIG. 13 is a view similar to FIG. 12 but showing the graft prosthesis being advanced out the distal end of the laparoscope in accordance with the preferred method of the present invention. FIG. 14 is a view similar to FIG. 13 but showing the graft prosthesis being further advanced out the distal end of the laparoscope in accordance with the preferred method of the present invention. FIG. 15 is a view similar to FIG. 14 but showing the graft prosthesis being yet further advanced out the distal end of the laparoscope in accordance with the preferred method of the present invention. FIG. 16 is a view similar to FIG. 15 but showing the laparoscope removed from the surgical incision and showing the graft prosthesis after it had reverted back to its prerolled configuration in accordance with the preferred method of the present invention. FIG. 17 is a view similar to FIG. 16 but showing a third balloon-tip catheter having a balloon thereon and further having an expandable stent, in its unexpanded state, positioned over the balloon, advanced to a position within the blood vessel in accordance with the preferred method of the present invention. FIG. 18 is a view similar to FIG. 17 but showing the balloon of the third balloon-tip catheter inflated so as to expand the stent in to its expanded configuration in accordance with the preferred method of the present invention. FIG. 19A is a view similar to FIG. 18 but showing the third balloon-tip catheter removed from the blood vessel and showing the stent expanded to form an anastomosis between one end of the graft prosthesis and the blood vessel in accordance with the preferred method of the present invention. FIG. 19B is an enlarged schematic side elevational view showing a number of sutures tied to the sidewall of the blood vessel so as to secure the end portion of the graft and the stent thereto as a possible additional procedure in order to further ensure the integrity of the anastomosis of FIG. 19 A. FIG. 19C is a cross-sectional view taken along the line 19 C— 19 C of FIG. 19B as viewed in the direction of the arrows. FIG. 19D is a view similar to FIG. 19A but showing a laparoscope (depicted schematically) inserted through an incision in the epidermis of the body and into the peritoneal cavity, and further showing a grasper holding a curved needle with an end of a suture attached thereto wherein the distal end of the grasper is positioned at the upstream site. FIG. 19E is an enlarged schematic side elevational view showing a number of sutures tied to the sidewall of the blood vessel so as to secure the end portion of the graft thereto (without the use of the stent), wherein the end portion of the graft is positioned within the upstream isolated region, as an alternative procedure in forming an anastomosis between the end portion of the graft and the blood vessel. FIG. 19F is a cross-sectional view taken along the line 19 F— 19 F of FIG. 19E as viewed in the direction of the arrows. FIG. 19G is an enlarged schematic side elevational view showing a number of sutures tied to the sidewall of the blood vessel so as to secure the end portion of the graft thereto (without the use of the stent), wherein the end portion of the graft is positioned outside of the upstream isolated region, as another alternative procedure in forming an anastomosis between the end portion of the graft and the blood vessel. FIG. 19H is a cross-sectional view taken along the line 19 H— 19 H of FIG. 19G as viewed in the direction of the arrows. FIG. 20A is an enlarged side elevational view showing the anastomosis of FIG. 19 A. FIG. 20B is a cross-sectional view taken along the line 20 B— 20 B of FIG. 20A as viewed in the direction of the arrows. FIG. 20C is a cross-sectional view taken along the line 20 C— 20 C of FIG. 20A as viewed in the direction of the arrows. FIG. 21 is a view similar to FIG. 19A but showing a pair of clamps positioned on the blood vessel in accordance with the preferred method of the present invention. FIG. 22 is a view similar to FIG. 21 but showing an arteriotomy formed in the sidewall of the blood vessel in accordance with the preferred method of the present invention. FIG. 23 is a view similar to FIG. 22 but showing an anastomosis formed between the other end the graft prosthesis and the blood vessel in accordance with the preferred method of the present invention. FIG. 24 is a view similar to FIG. 23 but showing the first balloon-tip catheter and the second balloon-tip catheter removed from the blood vessel in accordance with the preferred method of the present invention. FIGS. 25-33 are views showing performance of a bypass grafting procedure in accordance with the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments and methods illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated devices and methods, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Referring now to the drawings, FIG. 1 shows a portion of a human body, generally designated by the reference numeral 10 , with an artery, the common iliac artery 12 , having an occluded segment, generally designated by the reference numeral 14 . Human body 10 is further shown having other arteries, in particular, aorta 16 , right common femoral artery 18 , left common femoral artery 30 and renal arteries 20 . In addition, human body 10 includes a right inguinal ligament 19 and a left inguinal ligament 29 . Human body 10 also includes an epidermis 13 (see e.g. FIG. 6 ). The preferred method disclosed herein describes the implantation of a graft to couple aorta 16 to right common femoral artery 18 thereby bypassing occluded segment 14 . FIG. 2 shows an enlarged view of aorta 16 , right common iliac artery 12 , occluded segment 14 , right common femoral artery 18 , left common femoral artery 30 , renal arteries 20 and right inguinal ligament 19 . In FIGS. 1 and 2, a blood vessel is shown, generally designated by the reference numeral 11 , which includes aorta 16 , right common iliac artery 12 , right common femoral artery 18 and left common femoral artery 30 . Blood vessel 11 , when not occluded, conveys blood from a point C within aorta 16 to a point D within right common femoral artery 18 (see FIGS. 1 - 2 ). However, due to the presence of occluded segment 14 , blood is substantially totally precluded from being conveyed from point C within aorta 16 to point D within right common femoral artery 18 via the direct route of right common iliac artery 12 . While the inventive method will hereinafter be described with regard to a substantially totally occluded segment of a blood vessel of a patient, it will be understood to one skilled in the art that the inventive method is equally effective for bypass of a partially occluded segment of a blood vessel. In addition, the inventive method is also useful for bypass of an aneurysmal segment of a blood vessel. Referring now to FIGS. 3-24, successive steps according to the preferred method of the present invention are depicted of the implantation of a graft prosthesis of the present invention to couple aorta 16 to right common femoral artery 18 thereby bypassing occluded segment 14 of blood vessel 11 . One step of the preferred method of the present invention comprises isolating a region of the area within the blood vessel 11 , located near a site 21 (see FIG. 4) upstream of occluded segment 14 , from fluid communication with the rest of the area within the blood vessel. There also exists a site 31 which is located downstream of occluded segment 14 (see FIG. 4 ). Upstream site 21 is located substantially adjacent the blood vessel 11 and designates a working area where the distal end of medical instruments and various medical devices may be positioned during the process of securing one end of a graft to the blood vessel. Upstream site 21 is located near blood vessel 11 so as to allow such distal end of medical instruments and medical devices to be appropriately manipulated at upstream site 21 to thereby successfully secure the one end of the graft to the blood vessel. Downstream site 31 is located substantially adjacent the blood vessel 11 and also designates a working area where the distal end of medical instruments, physician's hands and various medical devices may be positioned during the process of securing a second end of the graft to the blood vessel. Downstream site 31 is also located near blood vessel 11 so as to allow such distal end of medical instruments, physician's hands and medical devices to be appropriately manipulated at downstream site 31 to thereby successfully secure the second end of the graft to the blood vessel. Referring now to FIG. 3, a balloon-tip catheter 22 having a balloon 24 thereon is percutaneously inserted into blood vessel 11 via the right or left axillary artery (not shown). This step may be accomplished using standard catherization techniques. The distal end of catheter 22 is then advanced into aorta 16 until balloon 24 is positioned distal to renal arteries 20 as shown in FIG. 3 . Balloon 24 is then inflated to and maintained at a size such that fluid communication is substantially terminated in aorta 16 between the portion of blood vessel 11 proximal to balloon 24 and the portion of blood vessel 11 distal to balloon 24 . Since conventional balloon-tip catheters may not have a balloon thereon that possess the characteristics necessary to terminate fluid communication in the aorta as described above, modification may be readily made to an existing design of a conventional balloon-tip catheter to achieve the above desired results. One such modification would include providing a balloon on the catheter with is inflatable to an outer diameter which is larger than the inner diameter of the aorta. Another such modification would include providing a coarse textured outer surface to the balloon of the catheter. The above modification would provide increased frictional resistance between the inflated balloon and the sidewall of the blood vessel when force is applied to the balloon in the axial direction thereof. A balloon-tip catheter having a conventional design is available through Medi-tech, Incorporated of Watertown, Mass., as Order No. 17-207 (Description: OBW/40/8/2/100). Referring now to FIG. 4, a balloon-tip catheter 26 having a balloon 28 thereon and an open lumen defined therein is percutaneously inserted into blood vessel 11 via the left common femoral artery 30 . This step may be accomplished using standard catherization techniques. The distal end of the catheter 26 is then advanced into aorta 16 until balloon 28 is positioned proximal to the aortic bifurcation. Balloon 28 is then inflated to and maintained at a size such that fluid communication is substantially terminated in aorta 16 between the portion of blood vessel 11 proximal to balloon 28 and the portion of blood vessel 11 distal to balloon 28 . Since conventional balloon-tip catheters may not have a balloon thereon that possess the characteristics necessary to terminate fluid communication in the aorta as described above, modification similar to that described with respect to catheter 22 may need to be made to catheter 26 . In addition, further modification may need to be made to catheter 26 since a conventional balloon-tip catheter may not have an open central lumen defined therein which possesses a diameter large enough for the advancement therethrough of a compressed stent mounted on a balloon of another balloon-tip catheter as will be required by the preferred method of the present invention (see FIG. 17 ). Such further modification would be to create an open central lumen in catheter 26 that possesses a diameter larger than the outer diameter of the compressed stent which is mounted on the balloon of the balloon-tip catheter as referred to above. Due to the increased size requirements of catheter 26 as alluded to above, a surgical cut-down may need to be performed in order to expose left common femoral artery 30 . Such exposure would facilitate both placement of catheter 26 into blood vessel 11 and repair of such blood vessel following subsequent removal of such catheter therefrom. Temporary occlusion of the blood flow in the inferior mesenteric artery (not shown) by laparoscopic procedures may need to be performed in order to prevent the flow of blood from the inferior mesenteric artery into aorta 16 due to placement of inflated balloons 24 and 28 as discussed above. The region bound by balloon 24 of catheter 22 and balloon 28 of catheter 26 and the sidewall of blood vessel 11 contained therebetween defines a region 40 of the area within blood vessel 11 , located near site 21 upstream of occluded segment 14 , which is substantially isolated from fluid communication with the rest of the area within blood vessel 11 . Alternatively, the step of isolating the region of the area within blood vessel 11 , located near upstream site 21 , from fluid communication with the rest of the area within the blood vessel may be accomplished by laparoscopically placing a first clamp around the blood vessel 11 at the location where balloon 24 of the balloon-tip catheter 22 was described as having been inflated and also laparoscopically placing a second clamp around the blood vessel 11 at the location where balloon 28 of the balloon-tip catheter 26 was described as having been inflated. Another step according to the method of the present invention comprises making an arteriotomy in the sidewall of blood vessel 11 , near upstream site 21 , to create a communicating aperture between upstream isolated region 40 and the outside of blood vessel 11 . Referring now to FIG. 5, right common femoral artery 18 and right inguinal ligament 19 are exposed via a surgical incision 17 . Such exposure is accomplished using standard surgical techniques. Insufflation of the peritoneal cavity is then performed using standard techniques associated with laparoscopy. A laparoscope 37 (see FIG. 6 ), having an open central lumen (i.e. a working channel) defined therein, is then inserted into human body 10 through the opening between right common femoral artery 18 and right inguinal ligament 19 . Laparoscope 37 may additionally include a fiber optic illumination device and a telescope for viewing. A tilt table may be used with the patient (i.e. human body 10 ) positioned thereon in order to maneuver the patient's abdominal contents away from the laparoscope insertion site and the area near upstream site 21 . Laparoscope 37 is then advanced toward upstream site 21 until its distal end is positioned thereat as shown in FIG. 6 . One or more additional laparoscopes and associated laparoscopic operating instruments may be employed using standard laparoscopic techniques to assist in the above positioning via direct visualization, tissue retraction and tissue dissection. One laparoscope which may be used in carrying out the preferred method of the present invention is available through Karl Storz Endoscopy-America, Incorporated of Culver City, Calif., as Catalog No. 26075A. Modification may be readily made to laparoscope 37 , such as rounding the distal edge thereof, in order to reduce the possibility of tissue trama as a result of advancement of laparoscope 37 within human body 10 . A book which discloses various standard laparoscopic techniques and standard associated laparoscopic operating instruments is entitled “Laparoscopy for Surgeons,” authored by Barry A. Salky, M.D., published by Igaku-Shoin Medical Publishers, Inc. of New York, N.Y., U.S.A. (1990), and the pertinent part of the disclosure of which is herein incorporated by reference. Referring now to FIG. 7, a puncture needle 39 is advanced through the open central lumen of laparoscope 37 until its distal end exits the laparoscope. Thereafter, needle 39 is manipulated to penetrate through the sidewall of blood vessel 11 to the inside thereof, thus creating a puncture in the blood vessel. Needle 39 is then withdrawn and a scissors device 41 is advanced through the open central lumen of laparoscope 37 until its distal end exits the laparoscope (see FIG. 8 ). The scissors device is then manipulated to enlarge the puncture in the sidewall of the blood vessel. Scissors device 41 is then withdrawn from laparoscope 37 . One puncture needle which may be used in carrying out the preferred method of the present invention is available through Karl Storz Endoscopy-America, Incorporated of Culver City, Calif., as Catalog No. 26178R. Additionally, one scissors device which may be used in carrying out the method of the present invention is available through Karl Storz Endoscopy-America, Incorporated of Culver City, Calif., as Catalog No. 26178PS. It should be noted that if upstream isolated region 40 was not substantially isolated from fluid communication with the rest of the area within the blood vessel, the act of making an arteriotomy in the sidewall of blood vessel 11 near upstream site 21 would cause significant blood leakage out of blood vessel 11 and such blood leakage may be fatal to the patient. According to another step of the method of the present invention, a graft prosthesis is positioned so that one end of the graft is located substantially adjacent blood vessel 11 at downstream site 21 and the other end of the graft prosthesis is located substantially adjacent blood vessel 11 at downstream site 31 . The above positioning step includes the step of advancing the graft prosthesis within the human body 10 with a medical instrument. One type of graft prosthesis which may be used is a graft, generally designated by the reference numeral 60 and shown n FIGS. 9A-9E. Graft 60 includes a body portion 61 having a length slightly larger than the distance between upstream site 21 and downstream site 31 . Graft 60 has an outwardly extending flanged end portion 62 as shown in FIGS. 9A, 9 C, 9 D and 9 E. End portion 62 is resiliently maintained outwardly extending by four springs 64 A- 64 D as shown in FIGS. 9 B and 9 E- 9 I. In their relaxed state, springs 64 A- 64 D maintain end portion 62 within a plane P 1 as shown in FIG. 9 A. It should be noted that a number of springs other than four may be used, if desired, to maintain end portion 62 outwardly extending as previously shown and described. Graft 60 further includes a second end portion 63 having a design similar to that of a conventional prosthetic graft as shown in FIG. 9 A. Graft 60 is preferably made of synthetic fibers. By way of example, graft 60 can be made from the material sold under the trademark Dacron by E. I. du Pont de Nemours & Co., Inc. of Wilmington, Del. Body portion 61 and end portion 62 are integrally formed together with springs 64 A- 64 D maintained integrally within the end portion 62 and a portion of the sidewalls of body portion 61 as shown in FIGS. 9B and 9E. Graft 60 maintains its shape as shown in FIGS. 9A-9E absent application of external forces thereto and also graft 60 will revert back to such shape upon termination of such external forces thereto. Graft 60 is positioned within the open central lumen defined in laparoscope 37 . In order to achieve the above, graft 60 is preferably rolled into a substantially cylindrical shape as shown in FIGS. 10A and 10B. End portion 62 of graft 60 is manipulated to lie substantially parallel to body portion 61 of graft 60 while graft 60 is in its rolled configuration as shown in FIG. 10 A. The outer diameter of graft 60 , in its rolled configuration, from point W to point Y is larger than the outer diameter of the rolled graft from point Y to point Z as shown in FIG. 10 A. The above is due to the angular construction of end portion 62 as shown in FIG. 9 A. The outer diameter of the rolled graft from point W to point Y is slightly smaller than the inner diameter of laparoscope 37 . As a result, in its rolled configuration, graft 60 can be positioned within the open central lumen of laparoscope 37 . Moreover, graft 60 can be maintained in its rolled configuration while positioned in the central lumen of laparoscope 37 due to the inner diameter thereof. Graft 60 is then inserted into the proximal end of the central lumen of laparoscope 37 and advanced until its full length is entirely therein. A plunger 82 is insertable into the central lumen of laparoscope 37 as shown in FIGS. 11A and 11B. Plunger 82 has a length sufficient to span the length of laparoscope 37 . Plunger 82 enables an operator to selectively position graft 60 within body 10 . FIGS. 11A and 12 show graft 60 positioned in the distal portion of the central lumen of laparoscope 37 after being advanced by plunger 82 . Laparoscope 37 with graft 60 contained therein is then advanced and manipulated such that the distal end of the laparoscope is advanced through the communicating aperture near upstream site 21 and into isolated region 40 . While the plunger is held stationary, laparoscope 37 is then withdrawn axially over plunger 82 and graft 60 in the direction of arrow 84 as sequentially shown in FIGS. 13-15. This allows graft 60 in its rolled configuration to be delivered out the distal end of laparoscope 37 . FIG. 15 shows end portion 62 of graft 60 positioned within upstream isolated region 40 and end portion 63 of graft 60 positioned at downstream site 31 . Since graft 60 is no longer held in its rolled configuration by the inner diameter of the open central lumen of laparoscope 37 , graft 60 becomes unrolled and reverts to its prerolled configuration as shown in FIG. 16 . Injection of a saline solution into graft 60 , via end portion 63 , may be performed to facilitate the reverting of graft 60 to its prerolled configuration. Alternatively, an additional laparoscope may be used to manipulate graft 60 to its prerolled configuration. Alternatively, a balloon-tip catheter may be advanced into graft 60 via end portion 63 and the graft converted to its prerolled configuration by inflation and deflation of the balloon along various segments of the graft. Also shown in FIG. 16, end portion 62 of graft 60 is positioned within upstream isolated region 40 near upstream site 21 and end portion 63 of graft 60 is positioned at downstream site 31 while body portion 61 of graft 60 is positioned outside of blood vessel 11 . Note that end portion 62 has also reverted back to its prerolled configuration so that such end portion is outwardly extending relative to body portion 61 of graft 60 . Another step according to the preferred method of the present invention includes forming an anastomosis between end portion 62 of graft 60 and blood vessel 11 near upstream site 21 . A balloon-tip catheter 86 having a balloon 88 thereon and further having an expandable stent 90 , in its unexpanded configuration, positioned over balloon 88 is advanced through the open central lumen of catheter 26 until its distal end is located within upstream isolated region 40 near upstream site 21 (see FIG. 17 ). Catheter 86 is further advanced until balloon 88 is positioned substantially adjacent end portion 62 of graft 60 as shown in FIG. 17 . Balloon 88 is then inflated to expand stent 90 to its expanded configuration such that end portion 62 is secured between stent 90 and the sidewall of blood vessel 11 near upstream site 21 as shown in FIG. 18 . Balloon 88 is then deflated and catheter 86 is then removed from body 10 via the central lumen of catheter 26 . FIG. 19A shows body 10 after catheter 86 is removed therefrom. Moreover, FIGS. 20A-20C show end portion 62 of graft 60 being forced into the sidewall of blood vessel 11 by stent 90 (in its expanded configuration) such that graft 60 is secured to blood vessel 11 near upstream site 21 at its end portion 62 . One stent which may be used, with a minor degree of modification, in carrying out the preferred method of the present invention is disclosed in U.S. Pat. No. 4,776,337 issued to Palmaz on Oct. 11, 1988, the pertinent part of the disclosure of which is herein incorporated by reference. Such modification would be to provide stent 90 with an outer diameter (in its fully expanded configuration) that is larger than the inner diameter of blood vessel 11 near upstream site 21 . Note that stent 90 includes a plurality of intersecting bars 71 which span the orifice of graft 60 near end portion 62 as shown in FIG. 20 B. Intersecting bars 71 which span the above orifice do not substantially hinder blood flow through the graft orifice as demonstrated by the technical article entitled “Intravascular Stents to Prevent Occlusion and Restenosis After Transluminal Angioplasty” which was published in the Mar. 19, 1987 edition of the periodical “The New England Journal of Medicine,” the pertinent part of the disclosure of which is herein incorporated by reference. Further modification may be readily made to stent 90 whereby stent 90 would have an opening defined in its sidewall which is of similar dimensions to the orifice of graft 60 near end portion 62 . Such opening would have no intersecting bars traversing thereover. The above modification would allow stent 90 to be positioned within blood vessel 11 near upstream site 21 wherein the above opening would be substantially superimposed over the orifice of graft 60 near end portion 62 . This would allow blood to flow through the connection between blood vessel 11 and graft 60 near upstream site 21 in an unimpeded manner. As a possible additional procedure in order to further ensure the integrity of the anastomosis between end portion 62 of graft 60 and blood vessel 11 near upstream site 21 , a number of sutures 100 may be tied to the sidewall of blood vessel 11 so as to further secure end portion 62 and stent 90 to the sidewall of blood vessel 11 as schematically shown in FIGS. 19B and 19C. This is accomplished by inserting a laparoscope 102 (which is similar to laparoscope 37 ) having an open central lumen into human body 10 until its distal end is near upstream site 21 . Thereafter, a grasper 104 is advanced through the central lumen of laparoscope 102 . The grasper 104 has in its grasp a curved needle 106 having an end of suture 100 attached thereto as shown in FIG. 19 D. By manipulating the distal end of grasper 104 , the needle 106 and the end of suture 100 are passed through the sidewall of blood vessel 11 and end portion 62 of graft 60 and into blood vessel 11 . With continued manipulation, the needle 106 and the end of suture 100 are then brought back out of blood vessel 11 . The suture 100 is then tied by standard laparoscopic techniques. One article that refers to standard laparoscopic techniques for tying sutures is entitled “Laparoscopic Choledocholithotomy”, which was published in Volume 1, Number 2, 1991 edition of the “Journal of Laparoendoscopic Surgery” (Mary Ann Liebert, Inc., Publishers), pages 79-82, and another article that refers to standard laparoscopic techniques for tying sutures is entitled “Improvement in Endoscopic Hernioplasty: Transcutaneous Aquadissection of the Musculofascial Defect and Preperitoneal Endoscopic Patch Repair”, which was published in Volume 1, Number 2, 1991 edition of the “Journal of Laparoendoscopic Surgery” (Mary Ann Liebert, Inc., Publishers), pages 83-90, the pertinent part of both of the above articles of which is herein incorporated by reference. A number of other sutures 100 are then tied to the sidewall of blood vessel 11 and end portion 62 of graft 60 in a manner similar to that hereinbefore described so as to further secure end portion 62 to the sidewall of blood vessel 11 as schematically shown in FIGS. 19B and 19C. One or more additional laparoscopes and associated laparoscopic operating instruments may be employed using standard laparoscopic techniques to assist in the above suturing procedure. Of course, sutures 100 may be sewn in a conventional running fashion so as to secure end portion 62 to the sidewall of blood vessel 11 . Also, end portion 62 may be sutured to the sidewall of blood vessel 11 prior to the placement of stent 90 within blood vessel 11 . Alternatively, the step of forming an anastomosis between end portion 62 of graft 60 and blood vessel 11 near upstream site 21 may be accomplished by suturing alone (i.e. without the use of stent 90 ). In particular, once end portion 62 of graft 60 is positioned within upstream isolated region 40 near upstream site 21 as shown in FIG. 16, end portion 62 is sutured to the sidewall of blood vessel 11 as schematically shown in FIGS. 19E and 19F. Note that in this alternative step, end portion 62 is sutured to an interior portion of blood vessel 11 as schematically shown in FIGS. 19E and 19F. Also note that end portion 62 is sutured to the sidewall of blood vessel 11 so as to be positioned substantially adjacent a portion of the sidewall of blood vessel 11 which substantially surrounds the arteriotomy. This is accomplished by tying a number of sutures 110 to the sidewall of blood vessel 11 and end portion 62 of graft 60 so as to secure end portion 62 to the sidewall of blood vessel 11 as schematically shown in FIGS. 19E and 19F. The sutures 110 shown in FIGS. 19E and 19F are applied in the same manner as the sutures 100 shown in FIGS. 19B, 19 C and 19 D were applied as described above. Of course, sutures 110 may be sewn in a conventional running fashion so as to secure end portion 62 to the sidewall of blood vessel 11 . As a further alternative, the end portion 62 of graft 60 need not be positioned in upstream isolated region 40 but rather end portion 62 may be positioned adjacent the sidewall of blood vessel 11 so that the communicating aperture (i.e. the arteriotomy) in the sidewall of blood vessel 11 near upstream site 21 is aligned with the central passage of graft 60 . At this position, end portion 62 is sutured to the sidewall of blood vessel as schematically shown in FIGS. 19G and 19H. Note that in this further alternative step, end portion 62 is sutured to an exterior portion of blood vessel 11 as schematically shown in FIGS. 19G and 19H. Also note that end portion 62 is sutured to the sidewall of blood vessel 11 so as to be positioned substantially adjacent a portion of the sidewall of blood vessel 11 which substantially surrounds the arteriotomy. This is accomplished by tying a number of sutures 120 to the sidewall of blood vessel 11 and end portion 62 of graft 60 so as to secure end portion 62 to the sidewall of blood vessel 11 as schematically shown in FIGS. 19G and 19H. The sutures 120 shown in FIGS. 19G and 19H are applied in the same manner as the sutures 100 shown in FIGS. 19B, 19 C and 19 D were applied as described above. Of course, sutures 120 may be sewn in a conventional running fashion so as to secure end portion 62 to the sidewall of blood vessel 11 . The remainder of the preferred method of the present invention is performed using standard surgical techniques. A book which discloses various standard surgical techniques is entitled “Color Atlas of Vascular Surgery,” authored by John S. P. Lumley, published by Wolfe Medical Publications Ltd. of Baltimore, Md. (1986), printed by W. S. Cowell, Ltd. of Ipswich, United Kingdom, and the pertinent part of the disclosure of which is herein incorporated by reference. More specifically, another step according to the preferred method of the present invention comprises isolating a region 50 of the area within blood vessel 11 , located near site 31 downstream of occluded segment 14 , from fluid communication with the rest of the area within the blood vessel. Referring now to FIG. 21, a pair of surgical clamps 53 and 55 are positioned on blood vessel 11 , one being placed upstream of isolated region 50 and the other being placed downstream of isolated region 50 . Another step according to the method of the present invention comprises making an arteriotomy in the sidewall of blood vessel 11 , near downstream site 31 , to create a communicating aperture between downstream isolated region 50 and the outside of the blood vessel 11 . End portion 63 of graft 60 is retracted by surgical forceps (not shown) to expose blood vessel 11 near downstream site 31 (see FIG. 22 ). A scalpel puncture is then made in blood vessel 11 near downstream site 31 and thereafter the puncture is extended to the appropriate length with a pair of surgical scissors. FIG. 22 shows the communicating aperture defined in the sidewall of blood vessel 11 , near downstream site 31 . Another step according to the preferred method of the present invention comprises forming an anastomosis between end portion 63 of graft 60 and blood vessel 11 near downstream site 31 . Graft 60 is then cut to an appropriate length and thereafter end portion 63 is cut an appropriate shape for attachment to blood vessel 11 . End portion 63 of graft 60 is then surgically stitched with suture 65 to blood vessel 11 near downstream site 31 as shown in FIG. 23 . Clamps 53 and 55 are then removed from blood vessel 11 , and moreover, balloons 24 and 28 are then deflated and thereafter catheters 22 and 26 are removed from body 10 as shown in FIG. 24 . This allows blood to flow to former upstream isolated region 40 . Once blood flow reaches former upstream isolated region 40 , a flow of blood will enter graft 60 and flow therethrough to former downstream isolated region 50 thereby bypassing occluded segment 14 . Consequently, proper blood flow will now exist in body 10 from point C within aorta 16 to point D within right common femoral artery 18 as a result of performing the above described method of bypass of occluded segment 14 . While the invention has been described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments and methods have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. For instance, it is possible that left common femoral artery 30 and left inguinal ligament 29 could be exposed via a surgical incision similar to that of incision 17 as hereinbefore described. Thereafter, a Y-shaped graft could be utilized instead of graft 60 as hereinbefore disclosed. The Y-shaped graft could be advanced in a rolled configuration through laparoscope 37 and delivered to a position substantially adjacent blood vessel 11 similar in manner to that hereinbefore described. An additional laparoscope could be inserted into human body 10 through the opening defined between left common femoral artery 30 and left inguinal ligament 29 in a manner substantially similar to that hereinbefore described with respect to the insertion of laparoscope 37 into human body 10 . The additional laparoscope could be advanced toward the left limb of the Y-shaped graft and thereafter used to grasp such limb and pull it toward left common femoral artery 30 and subsequently out of the surgical incision near the left common femoral artery. The end portion of the left limb of the Y-shaped graft could be cut to an appropriate length and shape, and thereafter, an anastomosis could be made between such end portion and left common femoral artery 30 similar in manner to that hereinbefore described with regard to right common femoral artery 18 and end portion 63 of graft 60 . Moreover, for example, in an alternative embodiment of the present invention, it is possible that a graft 200 may be utilized which would be similar to graft 60 hereinbefore described, however, both end portions of such graft 200 could be similar in structure to end portion 62 of graft 60 (see FIGS. 29 - 33 ). In other words, each graft end could posses an end portion that is resiliently maintained outwardly extending relative to the body portion of the graft 200 . A catheter 202 could be placed into blood vessel 11 at right femoral artery 18 and advanced toward occluded segment 14 (see FIG. 25 ). Prior to arriving at occluded segment 14 , the distal end of the catheter 202 could be manipulated and guided out of blood vessel 11 through a puncture site 204 laparoscopically created in the blood vessel in a manner similar to that hereinbefore described (see FIG. 26 ). The catheter 202 could then be advanced substantially adjacent blood vessel 11 over and past occluded segment 14 (see FIG. 27 ). One or more additional laparoscopes could assist in the above advancement (see also FIG. 27 ). The distal end of the catheter 202 could then be manipulated and guided to reenter blood vessel 11 at a site upstream of occluded segment 14 through a puncture site 206 laparoscopically created in blood vessel 11 in a manner similar to that hereinbefore described (see FIG. 28 ). The graft 200 having a resiliently outwardly extending end portion at each end thereof could then be advanced in a rolled configuration through the catheter 202 and delivered to a position substantially adjacent blood vessel 11 similar in manner to that hereinbefore described with respect to graft 60 and laparoscope 37 (see FIGS. 29, 30 , 31 ). The graft 200 could have a predetermined length equal to a length slightly larger than the distance between the puncture site 206 located upstream of occluded segment 14 and the puncture site 204 located downstream of occluded segment 14 . As a result, the distal end portion of the graft 200 could be positioned within blood vessel 11 at a location upstream of occluded segment 14 and the proximal end portion of the graft 200 could be positioned within blood vessel 11 at a location downstream of occluded segment 14 while the body portion of the graft 200 could be positioned substantially adjacent and outside of blood vessel 11 (see FIGS. 29, 30 , 31 ). Of course, an area within the blood vessel near each end portion of the graft 200 could be isolated from fluid communication with the rest of the area within the blood vessel in a manner substantially similar to that hereinbefore described with respect to upstream isolated region 40 . After being advanced out of the distal end of the catheter 202 , the graft 200 (including each outwardly extending end portion) could revert back to its prerolled configuration as hereinbefore described with respect to graft 60 (see FIG. 32 ). Thereafter, a stent 208 could be placed, in an expanded configuration, adjacent each of the end portions of the graft 200 within blood vessel 11 in order to secure such end portions of the graft 200 to blood vessel 11 as hereinbefore described with respect to stent 90 and end portion 62 of graft 60 (see FIG. 33 ).
Minimally invasive techniques utilized in bypass grafting are disclosed. For instance, a method of implanting an end portion of a graft in the body of a patient during a bypass grafting procedure includes the steps of (i) advancing a medical instrument within a circulatory system of said body, (ii) guiding a distal end of said medical instrument out of said circulatory system through an opening defined in said circulatory system after said medical instrument advancing step, (iii) advancing said end portion of said graft within said medical instrument after said guiding step, and (iv) securing said end portion of said graft to a blood vessel of said circulatory system after said end portion advancing step.
8
FIELD OF THE INVENTION The invention relates to the use of a viscosity modifier in replacement of a portion of deionized water to significantly reduce dishing of large metal surfaces that are embedded in a pattern along with small metal surfaces in a dielectric during CMP (chemical mechanical polishing). In general, the planarization of large metal surfaces that are part of a pattern along with small metal surfaces during CMP processes on metal patterns embedded in a dielectric, such as a silicon dioxide wafer, is accomplished by increasing the viscosity of the polishing slurry by adding a viscosity modifier in amounts between about 0.1-50 volume percent, in order to obtain significantly less dishing than would be the case when using deionized water alone and abrasive particles, oxidizers, and other chemicals including dispersants and surfactants. DESCRIPTION OF THE PRIOR ART During chemical-mechanical polishing (CMP) of materials such as interlayer dielectrics used in the manufacture of integrated circuits and other electronic devices, a slurry is generally used in conjunction with a polishing pad to facilitate the removal of an insulator, dielectric, or metal pattern material. In many of these CMP applications, the insulating or dielectric material is SiO 2 , and in an aqueous environment the surface undergoes a hydration reaction with H 2 O to produce a surface network of hydroxylated Si molecules. However, when the metal is a large surface that is part of a patterned metal design embedded in a dielectric on which other layers and a substrate are attached, the use of a CMP process to polish the patterned metal creates a severe amount of dishing in the larger metal features. U.S. Pat. No. 5,769,689 discloses compositions for a method of polishing a workpiece comprised of silicon dioxide wherein the surface of the workpiece is exposed to a polishing composition comprising water, submicron SiO 2 particles, a soluble inorganic salt at a concentration below the critical coagulation concentration for the composition, and the pH of the composition is adjusted to within a range of about 9-10 by the addition of a soluble amine. Kumar et al., "CHEMICAL-MECHANICAL POLISHING OF COPPER IN GLYCEROL BASED SLURRIES", Mat. Res. Soc. Symp. Proc. Vol. 427, pps 237-242 (1996), discloses the use of a slurry containing glycerol and Al 2 O 3 abrasive for CMP processing of a copper metal surface to render the copper suitable as an interconnect fabrication. The process is an alternative to reactive ion etching of copper. A chemical-mechanical polishing technique for LSI's to address the problem of dishing is disclosed in U.S. Pat. No. 5,607,718, in which a number of compounds are added to decrease the solution velocity and suppress dishing. These compounds include a number of thickeners such as silicates, glucose, tragacanth gum and agar. Nogo et al., "SLURRY ENGINEERING FOR SELF-STOPPING, DISHING FREE SiO 2 --CMP", IEDM, pages 349-352, ©1996 IEEE, discloses a slurry in which a surfactant was added to a conventional CeO 2 slurry for SiO 2 in chemical mechanical polishing (CMP) to obtain global planarization within a chip without any stopgoing layer or design limitations. U.S. Pat. No. 4,588,474 discloses a cleaning treatment on a metal surface wherein glycerin is added to the solution along with other additives to obtain a smoother and more uniform surface. These solutions contain a caustic, a nitrate or nitrite, and optionally, a diol or polyol such as ethylene glycol or glycerin, and the workpiece is an aluminum alloy. An electrochemical polishing technique for metal removal and planarization of various components in various stages of microelectronic fabrication is disclosed in U.S. Pat. No. 5,567,300. This patent is directed to feature removal, and uses a non-viscous polyol to enhance removal. Glycerin, which has a viscosity at room temperature of 1500 times that of water, is used in electroetching to increase the electrolyte viscosity and promote polishing. A significant disadvantage of the processes in the foregoing patent and literature references is that, there is no acknowledgement of the need to modify the slurries used in CMP by a viscosity modifier to enable prevention of severe dishing in larger metal features of a patterned metal embedded in a dielectric onto which other layers and a substrate are attached, when subjecting this workpiece to chemical mechanical polishing. SUMMARY OF THE INVENTION One object of the present invention is to provide a composition or slurry capable of preventing severe dishing of large metal surfaces embedded along with small metal surfaces in a dielectric, when the workpiece containing these metal features in the dielectric is subjected to chemical mechanical polishing (CMP). Another object of the present invention is to provide modification of the viscosity of a composition or slurry used in chemical mechanical polishing by replacement of a portion of deionized water in the slurry with a viscosity modifier that will provide significant reduction of severe dishing of large metal surfaces embedded in a pattern along with small metal surfaces in a dielectric, when the workpiece containing these metal features in the dielectric is subjected to CMP. A yet further object of the present invention is to provide a slurry that is improved by the addition of a viscosity modifier added in amounts from 0.1 to 50 volume percent, to significantly impede severe dishing of large metal surfaces embedded in a pattern along with small metal surfaces in a dielectric, when the workpiece containing the metal features in the dielectric is subjected to CMP. In general, the invention is accomplished by providing a deionized composition in which a portion of the deionized water is replaced with from about 0.1-50 volume percent of a viscosity modifier, and utilizing the viscosity modified slurry along with a suitable abrasive to polish a workpiece containing large metal surfaces embedded along with small metal surfaces in a pattern in a dielectric, and thereby prevent severe dishing of large metal surfaces during CMP. The composition for reducing dishing in patterned large metal surfaces embedded along with small metal surfaces in a dielectric as a workpiece during chemical polishing, consist essentially of: a viscosity increasing amount of a viscosity enhancer that is non-reactive, polyhydric alcohol selected from glycerol or polyethylene glycol, in replacement of a portion of deionized water in a slurry containing an abrasive; wherein the viscosity enhancer is present in amounts up to 50 volume percent of deionized water, and the composition is characterized by a viscosity from between 3.4 to 12 cps. The method for reducing dishing in patterned large metal surfaces embedded along with small metal surfaces in a dielectric as a workpiece during chemical mechanical polishing, comprises: exposing the surface of the workpiece to a polishing composition comprising a viscosity increasing amount of a viscosity enhancer that is a non-reactive polyhydric alcohol selected from glycerol or polyethylene glycol, in replacement of a portion of deionized water in a slurry containing an abrasive, wherein said viscosity enhancer is present in amounts up to 50 volume percent of deionized water; and the composition has a viscosity of between 3.4 to 12 cps. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional view of a workpiece depicting a pattern of large and small metal surfaces embedded in a dielectric, and wherein other layers and substrate are attached to the dielectric, prior to CMP. FIG. 2 is a cross-sectional view of a workpiece that has progressed half way through chemical-mechanical polishing, with part of the metal surface removed. FIG. 3 is a cross-sectional view of a workpiece showing completion of CMP, wherein blanket metal has been removed, and the metal remains only in patterns. FIG. 4 is an enlarged cross-sectional view of the workpiece of FIG. 3 showing the larger metal features characterized by more severe dishing as a result of prior art CMP. FIG. 5 is an enlarged cross-sectional view of a workpiece showing larger metal features not characterized by severe dishing as a result of subjecting the workpiece to a slurry containing from 0.1 to 50 volume percent of glycerol as a viscosity modifier in replacement of a portion of deionized water. FIG. 6 is a graph showing metal pad and line recess at various locations of wafers or workpieces having a pattern of large and small metal surfaces embedded in a SiO 2 dielectric subjected to CMP using the invention slurry containing from 0.1 to 50% by volume of glycerol in replacement of deionized water. DETAILED DESCRIPTION OF THE INVENTION The foregoing and other objects and advantages of the invention will be better understood by resort to the following detailed description of the preferred embodiments of the invention. In order to protect the metal features or lines from excessive dishing in chemical-mechanical polishing without the addition of dummy structures or hard mask, the invention process introduces a viscosity enhancer or modifier into the slurry. The slurry viscosity can be increased by the addition of any viscosity enhancer or modifier; however, in the context of the invention, preferred enhancers or modifiers are non-reactive, polyhydric alcohol containing materials. Most preferred are glycerol and polyethylene glycol. The glycerol or polyethylene glycol replaces a portion of the deionized water in the aqueous-based slurry up to an amount of about 50% by volume. The introduced high viscosity brought about by the enhancer limits the momentum and/or mass transfer of slurry abrasives and reactants/products of chemical reactions, and subsequently slows down the removal rate of the recessed metal features or lines of the microelectronic device. The improvement of lessened dishing is most readily observed in the large metal features of the metal pattern in the work piece containing the metal features in the dielectric where dishing is usually easily observed. Although not wishing to the bound by a theory as to how prevention of severe dishing is accomplished, it is nevertheless believed that the use of a non-reactive, polyhydric alcohol to replace a portion of deionized water in the aqueous-based slurry induces a limiting effect of the material removal from the large metal surface area and eventually renders a desired and minimum large metal pad dishing after CMP processes as a result of the introduction of the viscosity enhancer into the slurry. EXAMPLE A CVD tungsten film was used as the patterned metal surface in a SiO 2 dielectric in the form of a wafer. The polishing slurry consisted of 5 weight percent alumina abrasive, an oxidizer and varying concentrations of glycerol ranging from about 0.1 to about 50% by volume of the deionized water. The solution was mixed to homogeneity prior to polishing in order to ensure that there was not settling of these slurry particles. TABLE I shows a comparison of the slurry viscosity based upon the percent by volume of glycerol replacing deionized water. TABLE I______________________________________Volume % Glycerol Slurry Viscosity (cps)______________________________________0 3.425 5.750 12______________________________________ The primary abrasive sizes of alumina range from between about 0.01 μm to about 0.3 μm, and about 100 ml of slurry is delivered to the polishing pad prior to the beginning of polishing and then delivered at a rate of up to about 350 ml/min during the polishing step. FIG. 1, shows a cross-sectional view of a workpiece depicting a metal 10 having a pattern of large L and small S metal surfaces embedded in a dielectric 11, and wherein other layers and a substrate designed by arrow 12 are attached, prior to chemical-mechanical polishing (CMP). As may be seen from the cross-sectional view of FIG. 2, part of the metal surface 10 is removed to surface 20 half way through the chemical-mechanical polishing step, and the dielectric 21 remains substantially unaltered. From the enlarged cross-sectional view of FIG. 3, which shows completion of the CMP step, the blanket metal has been removed, and only the large and small patterned metals PM remain in the dielectric. However, from the more enlarged cross-sectional view of FIG. 4, it is clearly seen that the larger metal feature or pattern has undergone more severe dishing D, as a result of the prior art of CMP step. As a result of the use of the viscosity enhanced slurry of the present invention, in which, from about 0.1 to about 50 volume percent of glycerol has been used in replacement of a portion of deionized water as a viscosity enhancer, the depth of the dishing DOTD in the large metal features shown in FIG. 5 has been substantially lessened by approximately two-thirds at the conclusion of the CMP step. The dotted area represents the extent of the improvement. The metal lost profile as a function of percent glycerol, probe pattern, and location of probe site are depicted in FIG. 6, which shows metal pad and line recess (dishing) as a result of using the glycerol volume percents of the invention on a wafer in the CMP step. Additional advantages and modifications will readily occur to those skilled in the art. Accordingly, the invention in its broader aspects is not limited to the specific details and illustrated examples shown and described herein. Therefore, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
A composition for reducing dishing in patterned large metal surfaces embedded in a dielectric as a workpiece during chemical mechanical polishing, comprising: a viscosity increasing amount of viscosity enhancer in replacement of a portion of deionized water in a slurry containing an abrasive.
2
CROSS-REFERENCE TO RELATED APPLICATIONS None. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not applicable. REFERENCE TO A MICROFICHE APPENDIX Not applicable. BACKGROUND Powered air purifying respirators (PAPRs) utilize a mechanism, such as a blower, impeller, fan or other mechanism, to draw ambient air through air purifying elements to remove contaminants from the air. PAPRs are designed to be human portable for use in atmospheres with solid and liquid contaminants, gases, and/or vapors to provide a useable and safe supply of breathable air where the concentrations of contaminants are not immediately dangerous to life or health and the atmosphere contains adequate oxygen to support life. PAPRs carry a self-contained power source such as a battery to energize a motor to drive the blower, impeller, or fan. The self-contained power source desirably is sized small enough so the PAPR is readily human portable and large enough that the PAPR can be used without recharging the power source for a portion of a work shift effective to promote efficient worker operation. SUMMARY A self-calibrating powered air purifying respirator (PAPR) is disclosed. The PAPR comprises an electric motor mechanically coupled to a blower, an air flow sensor, and a controller coupled to the air flow sensor and to the electric motor. The controller is configured to automatically execute a one-time self-calibration by driving the electric motor to a predefined operation point, receiving an indication from the air flow sensor, determining a reference parameter based on the indication from the air flow sensor, and storing the reference parameter, wherein after completion of the one-time self-calibration the controller controls the electric motor based on the stored reference parameter. A method of manufacturing a powered air purifying respirator is disclosed. The method comprises assembling a powered air purifying respirator, wherein the powered air purifying respirator comprises a blower, an electric motor coupled to the blower, an air flow sensor, and a controller coupled to the electric motor and to the air flow sensor. The method further comprises evaluating a calibration state of the powered air purifying respirator, the evaluation performed automatically by the controller and, when the calibration state is uncalibrated, driving the electric motor to a predefined operation point. The method further comprises comparing a sensor value output by the air flow sensor to an initial control reference value stored in a memory of the controller to determine a calibrated control reference value and storing the calibrated control reference value in the memory, wherein the controller is configured to control the electric motor based at least in part on the calibrated control reference value stored in the memory when the powered air purifying respirator is in a calibrated state. A method of operating a powered air purifying respirator in the field is disclosed. The method comprises powering on the powered air purifying respirator and evaluating a calibration state of a powered air purifying respirator, wherein the powered air purifying respirator comprises a blower, an electric motor coupled to the blower, an air flow sensor, and a controller coupled to the electric motor and to the air flow sensor, the evaluation performed automatically by the controller. The method further comprises, when the calibration state is uncalibrated, driving the electric motor to a predefined operation point and comparing a sensor value output by the air flow sensor to an initial control reference value stored in a memory to determine a calibrated control reference value. The method further comprises storing the calibrated control reference value in the memory and, after storing the calibrated control reference value in the memory, changing the calibration state of the powered air purifying respirator to calibrated. The method further comprises, when the calibration state is calibrated, driving the electric motor by the controller based at least in part on the calibrated control reference value and based on the sensor value output by the air flow sensor. These and other features will be more clearly understood from the following detailed description, taken in conjunction with the accompanying drawings and claims. BRIEF DESCRIPTION OF THE DRAWINGS For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts. FIG. 1 is an illustration of a control system according to an embodiment of the disclosure. FIG. 2 is an illustration of a memory according to an embodiment of the disclosure. FIG. 3 is a flow chart of a method according to an embodiment of the disclosure. FIG. 4 is a flow chart of a method according to an embodiment of the disclosure. FIG. 5 is a flow chart of a method according to an embodiment of the disclosure. FIG. 6 is an illustration of an exemplary computer system suitable for implementing an embodiment of the disclosure. DETAILED DESCRIPTION It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents. Powered air purifying respirators (PAPRs) are well known in the art. An exemplary PAPR is described in US patent application publication US 2011/0146682 A1 entitled “Sensor Apparatus and Method to Regulate Air Flow in a Powered Air Purifying Respirator” by Swapnil Gopal Patil, et al, published Jun. 23, 2011, U.S. patent application Ser. No. 12/645,044 filed Dec. 22, 2009, which is hereby incorporated by reference in its entirely. A PAPR may comprise a motor mechanically coupled to an air blower. As the motor turns the air blower, the air blower draws air through one or more filters and delivers breathable air to a user, for example via a hose to a face mask worn by the user. The PAPR may comprise a battery that provides power to drive the motor and a controller that regulates the speed of the motor to provide a controlled air flow rate. Ideally, all PAPRs of the same model and/or type would be manufactured so as to produce the design air flow objective based on a common control reference value, for example a set-point stored in a memory of the PAPR. In practice, however, due to variation among the components of the PAPR, relying on a common control reference value to control the PAPR does not produce equal air flows in different PAPRs. For example, unit-to-unit differences in electric motors, differences in air blowers, differences in switching mode power supplies (SMPSs), and differences in other components may contribute to producing different air flows when relying on a common control reference value. In one PAPR the common control reference value may produce an air flow that is less than the rate of air flow specified by a design, and the air flow may then fail to meet the applicable safety codes defining acceptable air flow rates. In another PAPR the common control reference value may produce an air flow that exceeds the rate of air flow specified by the design, and the battery of the subject PAPR may then discharge prematurely. The present disclosure teaches a PAPR that self-calibrates and establishes a calibrated control reference value for each individual PAPR that accommodates component variations within each PAPR, whereby the PAPR provides an air flow rate that meets the design specification without either deficient or excessive air flow. Turning now to FIG. 1 , a system 100 is described. In an embodiment, the system 100 comprises an air blower 102 , an electric motor 104 , a battery 106 , a switched mode power supply (SMPS) 108 , a controller 110 , a control reference 112 , a sensor 114 , and a summation junction 116 . It is understood that some components commonly present in PAPRs are not shown in FIG. 1 to avoid cluttering the illustration. For example, in an embodiment, the air outlet at the right hand side of the illustration may be coupled into an air hose attached to a face mask. In an embodiment, the system 100 may be varied in some ways, and some components may be combined. For example, in an embodiment, the control reference 112 may be integrated with the controller 110 , for example the control reference 112 may be stored in a memory location of the controller 110 . In an embodiment, the system. 100 may not employ the switched mode power supply 108 but instead some other form of electrical power modulation component that modulates electrical power delivered to the electric motor 104 under control of the controller 110 . In an embodiment, the system 100 may not employ the switched mode power supply 108 , and the controller 110 may comprise the circuitry for electrical power modulation and may connect directly to the electric motor 104 . In an embodiment, the output of the sensor 114 may be filtered before feeding into the summation junction 116 . For example, the output of the sensor 114 may be low-pass filtered to remove noise from the sensor signal. In an embodiment, the controller 110 may be an electronic controller or processor. Alternatively, the controller 110 may be an algorithm or firmware that is executed by a processor. The switched mode power supply 108 may deliver a pulsed width modulated electrical power output to the electric motor 104 that is characterized by a voltage amplitude and/or a pulse duration or width. By increasing the output pulse duration and/or pulse duty cycle of the switched mode power supply 108 , the controller 110 indirectly commands the electric motor 104 to turn faster and hence to increase the rate of air flow delivered by the air blower 102 . By decreasing the output pulse duration of the switched mode power supply 108 , the controller 110 indirectly commands the electric motor 104 to turn slower and hence to decrease the rate of air flow delivered by the air blower 102 . The controller 110 commands the electric motor 104 based on the difference between the control reference value 112 and the output of the sensor 114 calculated or determined by the summation junction 116 . The sensor 114 provides an indication of the air flow. In an embodiment, the sensor 114 comprises a first probe located in an airflow channel of the PAPR that measures a stagnation pressure in the airflow channel and a second probe located to measure a static pressure in the airflow channel. The sensor 114 compares the difference of pressures sensed by the first probe and the second probe to develop an indication of air flow rate. For further details of a differential pressure based air flow rate sensor, see U.S. patent application publication US 2011/0146682 A1 entitled “Sensor Apparatus and Method to Regulate Air How in a Powered Air Purifying Respirator” by Swapnil Gopal Patil, et al., identified and incorporated by reference above. In another embodiment, however, a different kind of sensor 114 may be used to provide an indication or air flow. As mentioned above, the output of the sensor 114 may be filtered to remove noise and to smooth the sensor output before processing by the summation junction 116 . As the value of the output of the sensor 114 drops below the control reference value 112 , the output of the summation junction 116 becomes positive and increases in magnitude the further the value of the output of the sensor 114 drops. The positive output of the summation junction 116 received by the controller 110 causes the controller 110 to drive the electric motor 104 faster and hence increases the air flow rate. As the value of the output of the sensor 114 rises above the control reference value 112 , the output of the summation junction 116 becomes negative and increases in magnitude the further the output of the sensor 114 increases. The negative output of the summation junction 116 received by the controller 110 causes the controller 110 to drive the electric motor 104 slower and hence decreases the air flow rate. The controller 110 may process the output of the summation junction 116 in various ways to provide for stability and smooth air flow. In steady state, the output of the summation junction 116 may be such that the air blower 102 maintains a substantially constant air flow rate. In an embodiment, the system 100 may be operated in either a calibration mode of operation or a normal mode of operation. In the calibration mode of operation, the controller 110 may drive the electric motor 104 to a predefined operation point in an open loop control fashion. For example, the controller 110 may drive the electric motor 104 by outputting a predefined pulse width modulation voltage amplitude command and a predefined pulse width modulation duration command and/or duty cycle command to the switched mode power supply 108 , and the switched mode power supply 108 may provide the commanded voltage amplitude and pulse duration or duty cycle electrical power output to the electric motor 104 . After waiting an amount of time that is effective to allow the electric motor 104 to reach steady state, a comparison between the output of the sensor 114 and an initial control reference value 112 may be performed. If there is a material difference between the output of the sensor 114 and the initial control reference value 112 , then the system 100 is not calibrated and either the air flow rate is excessive and hence battery life is unnecessarily shortened or the air flow rate is deficient and hence insufficient air flow is delivered to a user of the PAPR. In either case, a calibrated control reference value 112 is calculated and written into a memory location storing the control reference 112 . If there is no material difference between the output of the sensor 114 and the initial control reference value 112 , the system 100 is already calibrated, and the memory location storing the control reference 112 is allowed to retain the initial control reference value 112 . In an embodiment, a the difference may be compared to a predefined tolerance to determine if the system 100 is calibrated or not calibrated. Turning now to FIG. 2 , a memory 150 is described. The memory 150 may be part of a memory chip that is coupled to the controller 110 or may be part of a memory integrated with a processor chip. In an embodiment, the memory 150 comprises a first memory location 152 storing a calibration state of the PAPR, a second memory location 154 storing a control reference value 154 , and a third memory location 156 storing a control reference cyclic redundancy check (CRC) value. In alternative embodiment, the memory 150 may not comprise the third memory location 156 and may not store a control reference CRC value. In an embodiment, when the PAPR is first assembled and/or manufactured, the first memory location 152 may store an uncalibrated state value. The programming that implements the controller 110 , for example instructions to be executed by a processor, may read the first memory location 152 after initial power-on of the system 100 , and when the first memory location 152 stores the uncalibrated state value, the processor: may perform the calibration operation described above. After the calibration operation is completed, the processor may write a calibrated state value into the first memory location 152 . Thereafter when the system 100 is powered on, the processor reads the first memory location 152 , determines that the system 100 is in the calibrated state, and implements closed loop control of the air flow based on the value stored in the second memory location 152 . It is understood that the control reference 112 of FIG. 1 may be identical to the second memory location 154 of the memory 150 in FIG. 2 . Alternatively, the second memory location 154 may be part of a non-volatile memory component while the control reference 112 may be part of a volatile memory component. On initiation of a control algorithm, the value stored in the second memory location 154 may be loaded into the control reference 112 before executing closed loop control of the air flow. In an embodiment, the processor may be a microcontroller, a microprocessor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), a complex programmable logic device (CPLD), or other processor. In an embodiment, the processor may provide the functionality and memory represented as the controller 110 , the control reference 112 , and the summation junction 116 in FIG. 1 . For example, the processor may execute logic instructions to perform the functions of the controller 110 and the summation junction 116 . In an embodiment, a cyclic redundancy check value is calculated on the control reference value and stored in the third memory location 156 at the same time that the control reference value is stored in the second memory location 154 . When the processor reads the control reference value from the second memory location 154 it may calculate a cyclic redundancy check value on the control reference value and compare with the cyclic redundancy check value that it reads from the third memory location 156 . If the calculated cyclic redundancy check value does not agree with the cyclic redundancy check value stored in the third memory location 156 , the processor may raise an alarm and/or power the system 100 off. Turning now to FIG. 3 , a method 200 is described. At block 202 , a PAPR is assembled. The PAPR may be assembled in a manufacturing plant. The PAPR may comprise an air blower, an electric motor coupled to the air blower, an air flow sensor and an electronic controller coupled to the electric motor and to the air flow sensor. In embodiment, the PAPR may be substantially the same as the system 100 described above with reference to FIG. 1 . The air flow sensor may comprise a differential pressure sensor having a first probe located in an airflow channel of the PAPR that measures a stagnation pressure in the airflow channel and a second probe located to measure a static pressure in the airflow channel as described above. In another embodiment, however, the air flow sensor may be a different kind of sensor. The PAPR may comprise a filter that filters and/or smooths the output of the air flow sensor. In an embodiment, the PAPR may comprise the air blower 102 , the electric motor 104 , the battery 106 , the switched mode power supply 108 , the controller 110 , the control reference 112 , the sensor 114 , and the summation junction 116 described above with reference to FIG. 1 . In another embodiment, however, the PAPR may be somewhat different. At block 204 , a calibration state of the PAPR is evaluated. The processing of block 204 may happen during power-on of the PAPR. For example, a processor and/or the controller 110 of the PAPR reads the first memory location 152 of the memory 150 . If the calibration state is calibrated 206 , the PAPR is already calibrated and the method 200 ends. If the calibration state is uncalibrated 206 , the processing proceeds to block 208 . At block 208 , the electric motor is driven to a predefined operation point. For example, the processor and/or controller 110 outputs a pulse width modulation command comprising a predefined voltage command and/or a predefined pulse width command to the switched mode power supply 108 , and the switched mode power supply 108 outputs an electrical power signal to the electric motor 104 , thereby driving the electric motor 104 to operate at a predefined operation point in an open-loop mode. The processing of block 208 may include a predetermined wait time that promotes allowing the electric motor 104 to reach steady state rotation. At block 210 , a difference between the sensor value output by the sensor and an initial control reference value is determined and stored in memory. For example, the summation junction 116 or the processor and/or the controller 110 subtracts the value output by the sensor 114 from the value stored in the second memory location 154 to determine a delta value Δ=initial control reference value−output of air flow sensor  Eq 1 It is understood that in an embodiment a filtered value of the output of the air flow sensor 114 may be used in this calculation. At block 212 , if the absolute value of the delta value is not greater than a predefined tolerance value, the PAPR is deemed calibrated, and the method 200 ends. If the absolute value of the delta value is greater than the predefined tolerance value, the processing proceeds to block 214 . At block 214 , a calibrated control reference value is determined by adding the initial control reference value and the delta value. calibrated control reference value=initial control reference value+Δ  Eq 2 At block 216 , the calibrated control reference value is stored in memory. For example, the calibrated control reference value is stored in the second memory location 154 and/or in the control reference 112 . In an embodiment, after the processing of block 216 , the first memory location 152 may be written with a calibrated state value. In an embodiment, a cyclic redundancy check value is calculated on the calibrated control reference value, and the cyclic redundancy check value is stored in the third memory location 156 . The process then exits. The processing of blocks 204 through 216 in method 200 may be performed by a processor and/or the controller 110 . The effect of the processing of method 200 is that the PAPR automatically self-calibrates during a first power-on cycle. The initial control reference value may be stored in the control reference 112 and/or in the second memory location 154 during a loading of firmware and/or software to the PAPR, for example during loading of firmware and/or software to the processor and/or controller 110 during initial assembly of the PAPR. The automatic self-calibration taught herein reduces the chances that the step of calibration may be omitted before the PAPR is shipped and that the PAPR may be operated by users in an uncalibrated mode. Further, the automatic self-calibration does not entail any human involvement in the calibration procedure and hence removes a rich source of calibration errors. Turning now to FIG. 4 , a method 250 is described. The method 250 may be performed in the field, after shipment of the PAPR from the manufacturing plant and/or from a distribution center. For example, the method 250 may be performed in the field after coupling a battery to the PAPR. The PAPR may comprise the system 100 described above with reference to FIG. 1 , but in another embodiment the PAPR may differ in some aspects from the system 100 described above. At block 252 , the PAPR is powered on. At block 254 , a calibration state of the PAPR is evaluated. For example, a processor and/or the controller 110 reads the first memory location 152 of the memory 150 . If the calibration state of the PAPR is determined to be calibrated 256 , the method 250 ends. If the calibration state of the PAPR is determined to be uncalibrated 256 , the processing proceeds to block 258 . At block 258 the electric motor is driven to a predefined operation point, substantially as described above with reference to block 208 in FIG. 3 . At block 260 , the sensor value output by the air flow sensor is compared to an initial control reference value stored in a memory to determine a calibrated control reference value. For example, the calibrated control reference value equals the initial control reference value plus the initial control reference value minus the sensed value. At block 262 , the calibrated control reference value is stored in memory, for example in the second memory location 154 . In an embodiment, a cyclic redundancy check value is calculated on the calibrated control reference value At block 264 the calibration state of the PAPR is changed to calibrated. For example, the calibrated state value is stored in the first memory location 152 . At block 266 the electric motor is driven based at least in part on the calibrated control reference value and based on the sensor value output by the air flow sensor. For example, the controller 110 drives the switched mode power supply 108 with command values that cause the switched mode power supply 108 to provide electrical power signals to the electric motor 104 based on the control reference 112 and/or the value read from the second memory location 154 and based on the output of the sensor 114 . In embodiment, the controller 110 may determine the commands for the electric motor 104 based on a filtered output of the sensor 114 . The processing of blocks 254 through 266 in method 250 may be performed by a processor and/or the controller 110 . Turning now to FIG. 5 , a method 280 is described. At block 282 if a trigger signal is received by the PAPR, for example by the processor and/or the controller 110 , the process proceeds to block 284 . The trigger signal may be any input provided by a user, for example by pressing and holding a button located on an exterior housing of the PAPR for a predefined time duration or by activating another control device. At block 284 , the calibration state of the PAPR is changed to the uncalibrated state. For example, the uncalibrated value is written to the first memory location 152 . The effect of the processing of block 284 is that the next time the PAPR is powered on, being in the uncalibrated state, the automated self-calibration process may occur as described above. A user may occasionally activate the trigger in order that the PAPR may recalibrate, for example after a predefined service interval or after a predefined number of uses or just to confirm to the user's satisfaction that the PAPR is calibrated. If the trigger is not activated, the processing of method 280 continues to loop through block 282 . In an embodiment, the processing of block 282 may occur during times when the processor and/or the controller 110 is idle or during low priority task execution scheduling. Alternatively, the processing of method 280 may be embedded in a control algorithm that continuously executes on the processor and/or on the controller 110 . FIG. 6 illustrates a computer system 380 suitable for implementing one or more embodiments disclosed herein, for example the controller 110 may share some of the structures of the computer system 380 . In an embodiment, the controller 110 and/or the summation junction 116 may be implemented in firmware as an algorithm that is repeatedly executed on a processor 382 of the computer system 380 . In an embodiment, the computer system 380 comprises the processor 382 (which may be referred to as a central processor unit or CPU) that is in communication with memory devices including secondary storage 384 , read only memory (ROM) 386 , random access memory (RAM) 388 , input/output (I/O) devices 390 , and network connectivity devices 392 . The processor 382 may be implemented as one or more CPU chips. In some embodiments, the computer system 380 may not comprise all of the components enumerated above. For example, in an embodiment, the computer system 380 may not have secondary storage 384 . Additionally, some of the components listed separately above may be combined in a single component, for example the processor 380 , the ROM 386 , and the RAM 388 may be integrated in a single component and/or single semiconductor chip. It is understood that by programming and/or loading executable instructions onto the computer system 380 , at least one of the CPU 382 , the RAM 388 , and the ROM 386 are changed, transforming the computer system 380 in part into a particular machine or apparatus having the novel functionality taught by the present disclosure. It is fundamental to the electrical engineering and software engineering arts that functionality that can be implemented by loading executable software into a computer can be converted to a hardware implementation by well known design rules. Decisions between implementing a concept in software versus hardware typically hinge on considerations of stability of the design and numbers of units to be produced rather than any issues involved in translating from the software domain to the hardware domain. Generally, a design that is still subject to frequent change may be preferred to be implemented in software, because re-spinning a hardware implementation is more expensive than re-spinning a software design. Generally, a design that is stable that will be produced in large volume may be preferred to be implemented in hardware, for example in an application specific integrated circuit (ASIC), because for large production runs the hardware implementation may be less expensive than the software implementation. Often a design may be developed and tested in a software form and later transformed, by well known design rules, to an equivalent hardware implementation in an application specific integrated circuit that hardwires the instructions of the software. In the same manner as a machine controlled by a new ASIC is a particular machine or apparatus, likewise a computer that has been programmed and/or loaded with executable instructions may be viewed as a particular machine or apparatus. The secondary storage 384 is typically comprised of one or more disk drives or tape drives and is used for non-volatile storage of data and as an over-flow data storage device if RAM 388 is not large enough to hold all working data. Secondary storage 384 may be used to store programs which are loaded into RAM 388 when such programs are selected for execution. The ROM 386 is used to store instructions and perhaps data which are read during program execution. ROM 386 is a non-volatile memory device which typically has a small memory capacity relative to the larger memory capacity of secondary storage 384 . The RAM 388 is used to store volatile data and perhaps to store instructions. Access to both ROM 386 and RAM 388 is typically faster than to secondary storage 384 . The secondary storage 384 , the RAM 388 , and/or the ROM 386 may be referred to in some contexts as computer readable storage media and/or non-transitory computer readable media. The memory 150 described above with reference to FIG. 2 may be part of the ROM 386 or the RAM 388 . Likewise, the control reference 112 described above with reference to FIG. 1 may be stored in the RAM 388 . In an embodiment, on power on of the PAPR, the processor 382 reads the calibrated control reference value from the second memory location 154 , which may be stored in ROM 386 , reads the cyclic redundancy check value stored in the third memory location 156 , which may be stored in ROM 386 , calculates a cyclic redundancy check value over the calibrated control reference value read from the second memory location 154 , and compares the calculated cyclic redundancy check value to the stored cyclic redundancy check value. If the CRCs agree, the processor 382 may write the calibrated control reference value into the control reference 112 which may be stored in RAM 388 . On subsequent normal mode processing, the controller 110 may control the electric motor 104 based on accessing the control reference 112 stored in RAM 388 . If the CRCs do not agree, the processor may present an alarm and power off the PAPR. I/O devices 390 may include printers, video monitors, liquid crystal displays (LCDs), touch screen displays, keyboards, keypads, switches, dials, mice, track balls, voice recognizers, card readers, paper tape readers, or other well-known input devices. The network connectivity devices 392 may take the form of modems, modern banks, Ethernet cards, universal serial bus (USB) interface cards, serial interfaces, token ring cards, fiber distributed data interface (FDDI) cards, wireless local area network (WLAN) cards, radio transceiver cards such as code division multiple access (CDMA), global system for mobile communications (GSM), long-term evolution (LTE), worldwide interoperability for microwave access (WiMAX), and/or other air interface protocol radio transceiver cards, and other well-known network devices. These network connectivity devices 392 may enable the processor 382 to communicate with the Internet or one or more intranets. With such a network connection, it is contemplated that the processor 382 might receive information from the network, or might output information to the network in the course of performing the above-described method steps. Such information, which is often represented as a sequence of instructions to be executed using processor 382 , may be received from and outputted to the network, for example, in the form of a computer data signal embodied in a carrier wave. Such information, which may include data or instructions to be executed using processor 382 for example, may be received from and outputted to the network, for example, in the form of a computer data baseband signal or signal embodied in a carrier wave. The baseband signal or signal embedded in the carrier wave, or other types of signals currently used or hereafter developed, may be generated according to several methods well known to one skilled in the art. The baseband signal and/or signal embedded in the carrier wave may be referred to in some contexts as a transitory signal. The processor 382 executes instructions, codes, computer programs, scripts which it accesses from hard disk, floppy disk, optical disk (these various disk based systems may all be considered secondary storage 384 ), ROM 386 , RAM 388 , or the network connectivity devices 392 . While only one processor 382 is shown, multiple processors may be present. Thus, while instructions may be discussed as executed by a processor, the instructions may be executed simultaneously, serially, or otherwise executed by one or multiple processors. Instructions, codes, computer programs, scripts, and/or data that may be accessed from the secondary storage 384 , for example, hard drives, floppy disks, optical disks, and/or other device, the ROM 386 , and/or the RAM 388 may be referred to in some contexts as non-transitory instructions and/or non-transitory information. In an embodiment, the computer system 380 may comprise two or more computers in communication with each other that collaborate to perform a task. For example, but not by way of limitation, an application may be partitioned in such a way as to permit concurrent and/or parallel processing of the instructions of the application. Alternatively, the data processed by the application may be partitioned in such a way as to permit concurrent and/or parallel processing of different portions of a data set by the two or more computers. In an embodiment, virtualization software may be employed by the computer system 380 to provide the functionality of a number of servers that is not directly bound to the number of computers in the computer system 380 . For example, virtualization software may provide twenty virtual servers on four physical computers. In an embodiment, the functionality disclosed above may be provided by executing the application and/or applications in a cloud computing environment. Cloud computing may comprise providing computing services via a network connection using dynamically scalable computing resources. Cloud computing may be supported, at least in part, by virtualization software. A cloud computing environment may be established by an enterprise and/or may be hired on an as-needed basis from a third party provider. Some cloud computing environments may comprise cloud computing resources owned and operated by the enterprise as well as cloud computing resources hired and/or leased from a third party provider. In an embodiment, some or all of the functionality disclosed above may be provided as a computer program product. The computer program product may comprise one or more computer readable storage medium having computer usable program code embodied therein to implement the functionality disclosed above. The computer program product may comprise data structures, executable instructions, and other computer usable program code. The computer program product may be embodied in removable computer storage media and/or non-removable computer storage media. The removable computer readable storage medium may comprise, without limitation, a paper tape, a magnetic tape, magnetic disk, an optical disk, a solid state memory chip, for example analog magnetic tape, compact disk read only memory (CD-ROM) disks, floppy disks, jump drives, digital cards, multimedia cards, and others. The computer program product may be suitable for loading, by the computer system 380 , at least portions of the contents of the computer program product to the secondary storage 384 , to the ROM 386 , to the RAM 388 , and/or to other non-volatile memory and volatile memory of the computer system. 380 . The processor 382 may process the executable instructions and/or data structures in part by directly accessing the computer program product, for example by reading from a CD-ROM disk inserted into a disk drive peripheral of the computer system 380 . Alternatively, the processor 382 may process the executable instructions and/or data structures by remotely accessing the computer program product, for example by downloading the executable instructions and/or data structures from a remote server through the network connectivity devices 392 . The computer program product may comprise instructions that promote the loading and/or copying of data, data structures, files, and/or executable instructions to the secondary storage 384 , to the ROM 386 , to the RAM 388 , and/or to other non-volatile memory and volatile memory of the computer system 380 . In some contexts, the secondary storage 384 , the ROM 386 , and the RAM 388 may be referred to as a non-transitory computer readable medium or a computer readable storage media. A dynamic RAM embodiment of the RAM 388 , likewise, may be referred to as a non-transitory computer readable medium in that while the dynamic RAM receives electrical power and is operated in accordance with its design, for example during a period of time during which the computer 380 is turned on and operational, the dynamic RAM stores information that is written to it. Similarly, the processor 382 may comprise an internal RAM, an internal ROM, a cache memory, and/or other internal non-transitory storage blocks, sections, or components that may be referred to in some contexts as non-transitory computer readable media or computer readable storage media. While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented. Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.
A self-calibrating powered air purifying respirator (PAPR). The PAPR comprises an electric motor mechanically coupled to a blower; an air flow sensor, and a controller coupled to the air flow sensor and to the electric motor. The controller is configured to automatically execute a one-time self-calibration by driving the electric motor to a predefined operation point, receiving an indication from the air flow sensor, determining a reference parameter based on the indication from the air flow sensor, and storing the reference parameter, wherein after completion of the one-time self-calibration the controller controls the electric motor based on the stored reference parameter.
8
BACKGROUND OF THE INVENTION The invention herein is particularly concerned with the provision of a wheeled cart adapted for the storage, transport and dispensing of baseball and/or softball bats and balls. Conventionally, bats and balls are carried, rather haphazardly and awkardly, within flexible duffle bags and the like. At the site of the game, the equipment, if permanent racks are not available, will be laid out directly on the ground. The equipment will thus be exposed to adverse weather conditions, ground moisture, and the like. In addition, the equipment tends to get misplaced and is frequently underfoot. A baseball equipment cart is presented in O'Reilly et al, U.S. Pat. No. 3,876,223, issued Apr. 8, 1975. The O'Reilly cart, while adapted to accommodate bats and balls, does so on cantilevered supports and in a horizontal shelf-like compartment with the major portion of the O'Reilly cart taken to accommodate equipment other than bats and balls. Golf carts of a variety of different forms and constructions are also known, as exemplified by the following two U.S. patents: No. 3,707,279 Kaiser Dec. 26, 1972 No. 4,017,091 Wallen Apr. 12, 1977 Carts with transporting wheels and internal partitions will also be noted in the following U.S. patents: No. 2,964,328 Muir Feb. 20, 1959 No. 3,591,194 Vega July 6, 1971 SUMMARY OF THE INVENTION The present invention proposes a wheeled cart, of a readily assemblable and disassemblable construction, specifically adapted for the accommodation of bats and balls utilized in the playing of baseball and/or softball. The cart provides a complete enclosure for the bats and balls, affording substantial protection during both the storage and transporting of the equipment. By the same token, the cart is provided with a hinged cover which, upon an outward swinging thereof, both provides a useable platform and allows free access to the bats and balls stored within defined areas within separately formed compartments. The bats are mounted in parallel adjacent relation to each other, the balls stacking within a pair of pockets which also parallel the bats, thereby providing for a compact construction easily wheeled, carried, or stored, the overall height of the cart being only slightly greater than the length of the bats. Also of significance is the ability of the cart to selectively accommodate baseballs or softballs, or, if so desired, both baseballs and softballs. The cart is formed of multiple panels which, for ease of assembly and disassembly, are held together by screws, preferably engaged in preformed holes. When assembled, the cart includes a rectangular bottom panel, front and rear walls with opposed side walls extending therebetween, a hinged lid or top panel, and an internal partition dividing the interior of the cart into an enlarged bat receiving compartment and a relatively smaller ball receiving compartment. The bat compartment has the interior thereof divided into individual bat receiving spaces by means of pair of longitudinally spaced grids removably mounted on grid supports secured to the inner faces of the walls and partition which define the bat compartment. The ball compartment is divided into two ball pockets and a central miscellaneous storage section by means of two longitudinally slidable dividers or divider panels. Two sets of grooves are provided for each divider whereby the width of the pocket formed thereby can be adjusted to accommodate either baseballs or the larger softballs. An appropriate spacer will also be provided for selectively positioning within each pocket to conform the interior thereof to baseballs. The cart enclosing top lid will be hinge mounted to pivot from a closed position to an outwardly swung horizontal position paralleling the top of the cart and defining a support platform for use as a scorekeeper's table, a shelf for temporarily holding additional equipment, and the like. In order to dispense the balls from the elongated pockets, each of the dividers includes a laterally directed foot which underlies the adjacent ball stack whereby the balls will be elevated for selective removal thereof upon an upward sliding of the divider. The divider in turn will be provided with appropriate grip means. Additional objects and advantages of the invention will become apparent from the details of construction and manner of use as more fully hereinafter described and claimed. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a front perspective view of the bat and ball cart comprising the present invention; FIG. 2 is an enlarged vertical cross-section taken substantially on a plane passing along line 2--2 in FIG. 1; FIG. 3 is a vertical cross-sectional view taken substantially on a plane passing along line 3--3 in FIG. 2; FIG. 4 is a transverse cross-sectional view taken substantially on a plane passing along line 4--4 in FIG. 2; FIG. 5 is a bottom plan view; FIG. 6 is a perspective view of the upper portion of the cart with the cover in its open platform-forming position; FIG. 7 is a perspective detail of the cart with the near side wall removed and the various components exposed for purposes of illustration; and FIG. 8 is a perspective detail illustrating the grid construction within the bat compartment. DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now more specifically to the drawings, the combined bat and ball cart is generally designated by reference numeral 10. The cart 10 basically comprises a vertically elongated rectangular housing 12 defined by front and rear walls 14 and 16 interconnected by opposed side walls 18 and 20. As will be appreciated from FIGS. 1 and 4 in particular, the side walls 18 and 20 have the opposed vertical edge portions thereof overlapping the vertical edges of the front and rear panels for securement thereto, preferably by screws, 22, selected ones of which have been illustrated. The lower end of the housing 12 is closed by a bottom panel 24 which is received therein and retained by screws driven through the lower edge portions of the walls and into the periphery of the bottom panel. In order to further rigidify the construction and provide additional support for the bottom panel 24, a pair of transversely extending support strips or skids 26 can be provided in underlying relation to the bottom panel and the lower edges of the front and rear walls respectively. Access to the interior of the housing 12 is to be provided through the open upper end thereof. This open upper end is selectively closed by a cover or lid 28 including a flat top 30 with a depending rectangular peripheral flange 32. The peripheral flange 32 is of equal size with the upper end of the housing 12 and, in the closed position of the cover, seats directly on the periphery defined by the upper edges of the housing walls. A depending hasp 34 fixed to the front portion of the cover flange 32 selectively engages over a staple 36 affixed to the upper portion of the front wall 14 for a retention and/or locking of the cover as desired. The cover 28 is hingedly mounted to the rear wall 16, as will be best noted in FIG. 6, by appropriate angle hinges 38 which allow for an upward and rearward swinging of the cover 28 to a position wherein the rear portion of the cover flange 32 abutts against the outer surface of the rear wall 16 with the planar top 30 of the cover 28 horizontally positioned so as to provide a support platform for use as a scoring table, the storage of additional equipment, or the like. The housing is divided into two full height compartments, a bat compartment 40 and a ball compartment 42, by a full height vertical partition 44 positioned transversely between the front and rear walls 14 and 16. For ease of assembly, the partition 44 can be received within opposed grooves 46 defined in the inner faces or surfaces of the front and rear panels 14 and 16. The bat compartment 40 is divided into a plurality of laterally aligned vertical cells, each capable of receiving a single bat 48 and segregating the bat, for easy access thereto and protection thereof, from the adjacent bats. These cells are formed by at least two vertically spaced grids 50 defined by crossed and interlocked slats 52, each terminating in a free outer end portion adapted to nest within an appropriate upwardly directed slot 54 provided within a support strip 56. Each grid 50 is supported by four support strips 56 respectively affixed to the inner surface of the side wall 20, the opposed surface of the partition or partition wall 44 directed inward to the bat compartment 40, and the inner surfaces of those portions of the front and rear walls 14 and 16 which define the bat compartment. As will be noted from FIG. 2 in particular, the grids 50 are spaced vertically from each other and from both the upper and lower ends of the housing or bat compartment. Further, in order to define the individual bat receiving cells, it will be recognized that the grids are in vertical alignment with each other, providing in effect for the peripheral confinement of each bat 48 toward both the upper and lower ends thereof. While the illustrated grids define nine bat cells aligned in three rows of three, it will be appreciated that, depending upon the size of the bat compartment, grids defining a lesser or greater number of cells can be utilized. Referring now to the ball compartment 42, this compartment is divided into front and rear full height vertical ball pockets 58 by full height vertical dividers or divider panels 60, each received within one of two pairs of vertical guide slots 62 and 64 provided in the opposed faces of the end wall 18 and partition 44 which define the bat compartment. As will be best noted from FIG. 4, the divider 60 forming the front ball pocket 58 is received within the pair of grooves 64 furtherest from the adjoining front wall 14 to define a maximum area pocket. When so positioned, the pocket 58 is specifically adapted for the accommodation of the larger softballs. A positioning of the divider 16 in the pair of grooves 62 which are more closely positioned to the adjacent wall, as is the case with the rear pocket 58 of FIG. 4, results in a sizing of the pocket for the accommodation of the smaller baseballs. It is particularly desired that the pockets 58 be specifically sized for the balls to be received therein in that this avoids any tendency for the balls to jam, not withstanding the extended vertical stacking thereof, particularly during the dispensing of the balls as shall be described presently. Noting FIGS. 2 and 4, when the divider 60 is positioned so as to provide for the smaller area pocket for the accommodation of baseballs, the lateral width of the pocket is correspondingly also reduced by a full height vertical spacer or spacer strip 66 affixed to and along the inner surface of the side wall 18. The upper edge 68 of this spacer 66 may be slightly downwardly and inwardly inclined so as to facilitate an introduction of the baseballs. The dispensing of the balls from the ball pockets 58 is effected by means of a laterally directed foot 70 affixed rigidly to the lower end portion of each of the dividers 60 and directed into the corresponding pocket 58 in underlying relation to the lowermost ball of the stack of balls which, incidently, have been generally suggested at 72 in FIG. 2. The actual dispensing of the balls 72 from either pocket 58 is effected by a grasping of the upper end of the corresponding divider or divider panel 60, this being facilitated by a pair of finger holes 74 formed at the upper end thereof, and vertically raising the divider with the lower foot 70 upwardly moving the stack of balls for a selective manual withdrawal of the balls from the upper end of the housing. As will be appreciated, by sizing the pockets so as to retain the balls in an essentially straight stack, there is no tendency for the stack of balls to jam during the withdrawal thereof. It is for this reason in particular that the size of the pockets is adjustable by a selective positioning of the dividers 60, whereby the cart can be used alternatively for baseball equipment or softball equipment. Similarly, and in fact as illustrated, by the provision of one small pocket and one large pocket, both baseball and softball equipment can be simultaneously accommodated. Wheeled mobility for the housing 12 is provided for by a pair of wheels 76 positioned outward of the opposed side walls 18 and 20 and mounted on the opposed ends of a wheel axle 78 rotatably received through the lower rear corners of the side walls 18 and 20, immediately above the bottom panel 24 and immediately inward of the rear panel 16. Noting FIGS. 3 and 7 in particular, in order to avoid any interference of the axle 78 with the stack of balls within the rear ball pocket 58, through which the axle 78 extends, a small spacer block 80 is affixed to the upper surface of the bottom panel 24 within this rear pocket 58, defining in effect a small rear compartment in which the axle passes. The provision of this spacer block 80 of course requires that the associated ball retrieving foot 70 be affixed to the corresponding divider 60 at a point slightly above the lower end thereof whereby the foot rests on the block 80 rather than directly on the upper surface of the bottom panel 24. As a further means for assisting in the manipulation, carrying or positioning of the cart 10, a pair of appropriate hand grips or handles 82 can be affixed at spaced points to the front wall 14. A similar handle 84 will also normally be provided on the cover or lid 28. From the foregoing, it will be appreciated that a unique combined bat and ball cart has been defined. The cart, in addition to providing for the accommodation of both bats and balls, is convertible in the sense that the cart can be adapted to selectively accommodate either baseball equipment or softball equipment or, if so desired, a combination of both. The entire assembly is wheel mounted for a simplified transporting of the equipment. In addition, the wheels are so positioned relative to the base of the equipment confining housing as to enable a substantially vertical positioning of the housing, thus providing a convenient storage rack for use during actual games. The entire structure is specifically formed for ready assembly and disassembly, utilizing, basically, only screws in the assembly of the basic structural components with the interior partitions, dividers, and the like being received within slots, grooves, and the like. As such, the cart can be readily disassembled and compacted for shipping, storage or the like, and subsequently assembled as required.
A readily assemblable and disassemblable wheeled cart incorporating a first internal compartment having vertically aligned grids therein defining individual bat receiving cells, a second compartment divided into a pair of elongated pockets by dividers received in selected grooves in accordance with whether the pockets are to accommodate baseballs or softballs, and a cart-enclosing top hingedly mounted for outward swinging to a platform forming position. The pocket forming dividers include, in each instance, a laterally directed foot which underlies the pocket received balls for a vertical elevation of the balls upon a vertical shifting of the divider.
0
CROSS-REFERENCE TO RELATED APPLICATION This application is related to our commonly assigned, co-pending U.S Application Ser. No. 07,185,688 filed Apr. 25, 1988, and entitled "METHOD AND APPARATUS FOR MONITORING A PREDETERMINED YARN QUALITY AT A TEXTILE MACHINE, ESPECIALLY AT A FALSE-TWIST JET SPINNING APPARATUS". BACKGROUND OF THE INVENTION The present invention relates to a new and improved method for monitoring a predeterminate or predetermined yarn quality of a yarn or the like produced by a textile machine, especially a friction spinning apparatus, and further pertains to a new and improved friction spinning apparatus for performing the inventive method. In the context of this disclosure, the term "yarn" or equivalent expressions, are used in their broader sense to encompass not only yarns as such, but also threads and other filamentary material. In the production of yarn, the evenness of the yarn quality at each spinning position or location, as well as the comparative yarn quality between the individual spinning positions or locations, plays an important role. German Published Patent Application No. 3,517,763 A1, published Nov. 20, 1986, discloses a method and an apparatus for maintaining a predetermined yarn twist to enable checking or controlling the evenness of this yarn quality parameter. Direct measurement of yarn twist while the spinning process is in progress cannot be achieved. Accordingly, the yarn twist must be estimated with the aid of a yarn diameter measurement. This can be accomplished without contact between the yarn to be measured and the measuring device, i.e. can be measured only indirectly. 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 method and apparatus for reliably monitoring a predeterminate yarn quality in a manner which is not afflicted with the aforementioned shortcomings of the prior art constructions. Another and more specific object of the present invention aims at providing a new and improved method and apparatus for monitoring a predeterminate yarn quality, particularly by measuring the yarn tension at a textile machine, and specifically a friction spinning apparatus, in a highly reliable and accurate fashion and, when necessary, undertaking appropriate corrective measures to ensure for uniformity of the produced yarn or the like. Still a further significant object of the present invention aims at performing a direct measurement at the fabricated yarn formed from a fiber tube in order to obtain a highly reliable estimate of the yarn quality. Now in order to implement these and still further objects of the present invention, which will become more readily apparent as the description proceeds, the method for monitoring a predeterminate yarn quality is manifested, among other things, by the features that a yarn is fabricated by means of a friction spinning apparatus. The fibers delivered to a friction spinning element, such as a suction friction spinning drum or suction friction spinning disc, of the friction spinning apparatus are formed into a fiber tube from which there is formed the friction spun yarn. There is measured the mechanical tension of the running yarn in order to ascertain the yarn quality. The measured value of the mechanical tension of the running yarn is compared with a predeterminate tension or tolerance value or range constituting a reference or set value. Upon deviating from or falling outside such predeterminate tension or tolerance value or range, in other words, upon exceeding or overshooting or falling below or undershooting such predeterminate tension or tolerance value or range, the friction spinning apparatus is acted upon so as to cause a corresponding tension change or alteration in the yarn, namely a tension increase or tension decrease of the produced yarn. As alluded to above, the invention is not only concerned with the aforementioned method aspects, but also relates to a new and improved construction of a friction spinning apparatus for the performance of the inventive method. The friction spinning apparatus comprises friction spinning elements or means providing a friction spinning location or position for forming a fiber tube. The friction spinning elements can comprise a pair of coacting friction spinning drums or rolls or a friction spinning disc coacting with a conical or frusto-conical roller (herein generally simply conical roll or roller). The friction spinning location or position is defined by a suction zone or region provided at the outer surface of a suction friction spinning drum, also referred to as a perforated suction drum or simply suction drum, of the coacting pair of friction spinning drums or at the outer surface of the friction spinning disc which is subjected to the action of suction or vacuum. This suction zone or region is formed or established by a suction slot provided in a suction device, such as a suction nozzle. This suction nozzle bounds at the inner surface of the perforated suction drum or friction spinning disc, as the case may be. This inner surface is located opposite the aforementioned outer surface of such perforated suction drum or friction spinning disc. The suction nozzle sucks or draws air through the suction zone or region. The friction spinning drum or roll, also referred to as a counter-roll or drum, cooperating with the perforated spinning drum, or the conical roll or roller cooperating with the friction spinning disc each define a counter element. Each such counter element is arranged at a predeterminate distance from its therewith cooperating friction spinning element. In the case of the coacting pair of friction spinning drums the cooperating element is the perforated spinning drum, and in the case of the friction spinning disc and coacting conical roll or roller, the cooperating element is the friction spinning disc which is subjected to a suction or vacuum action. Following the spinning location or position, viewed in the direction of yarn travel of the running yarn, there is provided a yarn tension measuring device or unit which delivers a measuring or measurement signal indicative of the measured yarn tension. Additionally, there are provided means which alter the yarn tension. Such yarn tension altering means can, for instance, move the suction nozzle such that the suction slot thereof is either moved in the direction of rotation of the perforated spinning drum or the suction friction spinning disc or in the opposite direction. A further possibility for altering the yarn tension is to control the rotational speed of one of the friction spinning elements, such as the perforated spinning drum or the suction friction spinning disc, as a function of the measured yarn tension. Still a further possibility for altering the yarn tension, is to control the size of the nip or gap between the coacting friction spinning elements. Obviously, selected combinations of each of such various techniques are also possible. Also, display or indicator means for displaying the yarn tension can be provided on the basis of which the yarn tension can be altered by manually initiating the above described techniques, or else it is equally possible to provide control means to automatically operate the means for altering the yarn tension on the basis of the measured or measurement signal. 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 throughout the various figures of the drawings, there have been generally used the same reference characters to denote the same or analogous components and wherein: FIG. 1 illustrates part schematically a section of a friction spinning apparatus comprising a pair of coacting friction spinning elements, here shown as coacting friction spinning drums or rolls; FIG. 2 illustrates a top plan view of the friction spinning apparatus depicted in FIG. 1 but with certain parts or elements omitted to improve clarity in the representation while adding other parts or elements in order to complete the understanding of the friction spinning apparatus depicted in FIG. 1; FIG. 3 illustrates on a somewhat enlarged scale and part schematically and in cross-sectional view the friction spinning apparatus of FIG. 1, taken substantially along the line I--I thereof; and FIGS. 3A and 3B illustrate respective enlarged details of the arrangement of FIG. 3. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Describing now the drawings, it is to be understood that to simplify the showing thereof, only enough of the friction spinning apparatus, and the related structure or apparatus for monitoring a predeterminate yarn quality have been illustrated therein as are needed to enable one skilled in the art to readily understand the underlying principles and concepts of this invention. Turning now specifically to FIG. 1 of the drawings, the therein depicted exemplary embodiment of friction spinning apparatus comprises for instance, in known manner, an opening roller or roll 1 provided with an adjoining fiber transport passage or duct 2, the exit opening 3 of which is situated closely adjacent to a fiction spinning element, here shown as a suction drum 4 but without making contact with such suction drum 4 as also will be recognized by inspecting FIG. 3. As partly indicated at the region or location designated by reference numeral 5, the suction drum 4 constitutes a perforated suction drum which has a perforated region. Also, this suction drum or perforated suction drum 4 is provided in its interior with a suction nozzle 6 or equivalent suction generating device which is situated closely adjacent to the internal or inner wall 7 of the suction drum 4 without making contact therewith. With the aid of this suction nozzle 6, which is appropriately connected to a suitable conventional source of low pressure (not shown) as is well known in the friction spinning art, air is drawn or sucked through the fiber transport passage or duct 2 and through the perforations or holes 5a of the perforated region or location 5 of the perforated suction drum 4. As best seen by referring to FIGS. 2 and 3, the suction nozzle 6 comprises an upper wall 8 and a lower wall 9 as well as lateral closure walls 10 (indicated with dotted lines in FIG. 2). The suction nozzle 6 is also connected to a connector duct or tube 11 or equivalent structure. The walls 8, 9 and 10 of the suction nozzle 6 define a suction slot or slit 6a which is adapted to the interior or inner wall 7 and having the width or breadth B (FIGS. 1 and 3) and the length L (FIG. 2). The connector duct or tube 11 is rotatably supported in a rotary or rotational bearing 12, shown in a stationary housing portion 13, schematically illustrated in section in such FIGS. 1 and 2. A guide element 15 is mounted on the connector duct or tube 11 for rotation of such connector duct or tube 11 in order to be able to appropriately pivot the suction nozzle 6 about the axis of rotation 14 of the connector duct or tube 11. This guide element 15 bears by means of a slide or ramp surface 16 forming part thereof on a cam or cam member 17 or equivalent structure. On the one hand, this cam or cam member 17 is pivotably supported in a pivot bearing or bearing structure 19 fixedly connected with a stationary housing part 18, schematically conveniently indicated only by the hatching, and, on the other hand, is pivotably connected by means of a link or rod 20 with an adjusting or positioning motor 21. This adjusting or positioning motor 21, in turn, is fixedly connected with a fixed housing portion 22. Such adjusting or positioning motors 21 are of known construction and can be, for example, constituted by an electromagnetic adjusting or positioning motor. Instead of using for the friction spinning apparatus the perforated suction drum 4 and coacting counter-roll or drum 24, other types of cooperating friction spinning elements may be employed as previously indicated. For instance, as is known in the friction spinning art, there can be used an arrangement embodying an imperforate conical or frusto-conical roller coacting with a perforated disc to which suction is applied, as such an arrangement has been disclosed in British Patent No. 1,231,198, published May 12, 1971, as well as in the commonly assigned U.S. Pat. No. 4,660,371, granted Apr. 28, 1987, to which reference may be readily had. At the end remote from the connector duct or tube 11, the perforated suction drum 4 is rotatably supported in a rotary or rotational bearing 25 fixedly mounted in a stationary housing part or portion 26. The coacting friction spinning element, as above explained here shown as the imperforate counter-roll or drum 24 is arranged such that its lengthwise axis is substantially parallel to the lengthwise axis of the perforated suction drum or roll 4. In contrast to the construction of perforated suction drum 4, this counter-roll or drum 24 is, as stated, not a perforated roll or drum. Such counter-roll or drum 24 is rotatably supported in a rotary or rotational bearing 23. This rotary bearing 23 is guided for selective movement as a unit in the direction of the double-headed arrow C of FIG. 2 in a stationary slide mounting (not shown), but cannot be lifted off its guide structure. The perforated suction drum or suction drum 4 is driven by a suitable drive motor 27 fixed to a housing portion or part 26. The counter-roll or drum 24 is driven, for instance, by an elastic belt or belt member 28 or equivalent drive or power transmitting element stretched or trained around the perforated suction drum 4 and the counter-roll or drum 24 at any suitable location. A guide element 29 is secured to the rotation or rotary bearing 23 in order to control the movements of the counter-roll or drum 24 in one or the other of the directions indicated by the double-headed arrow C. The guide element 29 bears by means of a slide or ramp surface 30 on a cam or cam member 31 or equivalent structure. This cam 31 is pivotably supported in a fixedly mounted rotary or rotational bearing 32 and is connected by means of a joint or hinge connection 33 with a stationary adjusting or positioning motor 34. A compression or pressure spring 35 is fixedly arranged between the rotary bearing 23 and a fixed housing portion or part 36 on the side of the rotary bearing 23 which is located opposite the cam 31. A yarn or thread 37 or the like spun by the friction spinning apparatus is withdrawn as a running or travelling yarn in the direction of the arrow D by a conventional withdrawal or delivery roller or roll pair 38. A suitable yarn or thread tension measuring device 39 is provided before or upstream of the withdrawal or delivery roller pair 38 considered in the direction of yarn movement indicated by the arrow D. Such yarn or thread tension measuring devices 39 are known in the art, and one such suitable construction is commercially available, for example under the trade designation Electronic-Tensiometer R-1192 from the Swiss firm Rothschild Company of Traubenstrasse 3, CH-8002, Zurich, Switzerland. A measurement signal defining an output signal appearing on the output line 40 of the yarn tension measuring device 39 and representative of the momentarily measured yarn tension is received by a suitable control unit or device 41. This control unit or device 41 is of conventional design and details thereof do not constitute subject matter of the present invention. Basically, the control unit 41 has a reference or set input or input section 41a at which there can be set a desired reference or set value of the yarn tension or tolerance value or range with which there is then compared in a comparator 41b the yarn tension measured by the yarn tension measuring device and on the basis of such comparison there is delivered at the output side or section 41c of the control device 41 an output signal which perfects a suitable control operation for either increasing or decreasing the yarn tension as the need dictates and as will be described more fully hereinafter. Control units or devices suitable for such purposes are well known in the electrical and electronic arts as well as in the textile art. An example of a suitable control device which can be utilized in the arrangement of the present invention has been disclosed, by way of example and not limitation, in U.S. Pat. No. 4,275,483, granted June 30, 1981, to which reference may be readily had and the disclosure of which is incorporated herein by reference. In operation, a not particularly depicted fiber sliver or other appropriate fiber arrangement is fed into the opening roll 1 and conventionally separated at that location into individual fibers. These separated individual fibers are transported by means of the transport passage or duct 2 onto the surface of the perforated suction drum or roll 4. This procedure will be described in further detail with such fiber feed process is well known in the friction spinning art. The airstream issuing from the fiber transport passage or duct 2 is indicated by the arrow M in FIGS. 3A and 3B and the airstream flowing through the narrowest gap or nip F is indicated by the arrow N in such FIGS. 3A and 3B. These two airstreams are induced by the suction effect of the suction nozzle 6 prevailing along the width or breadth B and length L of this suction nozzle 6. As will be observed by referring to FIG. 3A, a fiber 42 deposited by the airstream M on the outer surface 7a of the suction drum 4 is transported on this drum surface 7a, as dictated by the direction of rotation E of the perforated suction drum 4 (FIG. 3) towards the narrowest gap or nip F until the leading fiber end 43 (FIG. 3A) is bent or curved by the lower or upwardly flowing airstream N and returned to such outer drum surface 7a in order to be transported once again in the direction of the arrow E. If this procedure is imagined not only for a single fiber 42 but for all of the delivered fibers, then it will be seen that a so-called fiber tube 44 is produced by this circulation or motion of the fibers. Due to the rotation direction indicated by the arrow E of the perforated suction drum 4 and the direction of rotation indicated by the arrow K of the counter-roll or drum 24, the produced fiber tube 44 rotates with a direction of rotation H (FIG. 3B) and with a peripheral speed essentially corresponding to the peripheral speed of the drums or rolls 4 and 24 i.e. practically without any slip. The yarn 37 thus produced condenses or constricts, in the direction of yarn movement indicated by the arrow D, from this fiber tube 44. This procedure has been described in the German Published Patent Application No. 2,919,316, published Nov. 22, 1979 and to which reference may be readily had and the disclosure of which is incorporated herein by reference. Now, if the suction nozzle 6 is shifted in the direction of rotation indicated by the arrow P (FIG. 3B), then the fiber tube 44 also moves in the same direction and becomes smaller in its cross-section and reaches a maximum reduction in its cross-section or cross-sectional area at the region of the narrowest gap or nip F. It has now been found that a higher thread tension and a higher twist level arise in the yarn 37 by virtue of this decrease in the yarn cross-section and as a result of the reinforced or augmented wedging effect of the fiber tube 44 located in the converging gap or nip F between the two coacting drums or rolls 4 and 24. As concerns the formed yarn 37, the aforementioned observations particularly apply to the yarn portion located before or upstream of the withdrawal or delivery roller or roll pair 38 considered in the direction of yarn movement indicated by the arrow D. The suction nozzle 6 can be selectively positioned by the control unit or device 41 which delivers at the output line 41d a suitable control signal, as dictated by the aforementioned operation of the yarn tension measuring device 38 which, as stated, inputs the momentarily measured yarn tension at the line or conductor 40 to the control unit 41. The delivered control or output signal appearing on the line 41d is fed to the adjusting or position motor 20 which acts via the cam 17 and slide surface 16 upon the guide element 15 and thus upon the connector duct or tube 11 in order to appropriately pivot or move the suction nozzle 6 in one or the other directions of pivotal movement thereof. The restoring moment or torque of the suction nozzle 6 and connector duct or tube 11 maintains the slide surface 16 of the guide element 15 in contact with the cam 17, but additionally or alternatively, there also could be provided for this purpose a suitable biasing element, such as a spring. A further parameter or variable for adjusting tension in the yarn 37 is adjustment of the narrowest gap or nip F. As the gap or nip F becomes smaller, the cross-section of the fiber tube 44 also decreases and thus the yarn tension in the yarn 37 is increased. Adjustment of the size of the gap or nip F can be accomplished in comparable fashion by the control unit or device 41 delivering at the output line 41e a suitable control signal which acts upon the adjusting or adjustment motor 34 so as to appropriately radially move the counter-roll or drum 24 through the action of the cam 31 upon the rotary bearing 23. A further possibility for controlling the tension of the yarn 37 is afforded when the control unit or device 41 delivers at the output line 41f a control signal which acts upon the drive motor 27 in order to control the rotational speed of the perforated spinning drum or roll 4. The control unit or device 41 determines whether the momentarily measured yarn tension (which also can be designated as thread tension) lies within a predetermined tolerance range or tension tolerance and, if this is not the case, causes in the aforedescribed manner a change in the width of the gap or nip F within a predetermined tolerance range or tolerance and/or pivoting of the suction nozzle 6 within a predetermined tolerance range or tolerance so as to again establish the desired or required yarn tension. Also, as above explained, modification of the yarn tension can be undertaken by controlling the rotational speed of the perforated spinning drum or roll 4. The magnitude of the change in the width of the gap or nip F including the tolerance range therefor, and/or the magnitude of the pivotal movement of the suction nozzle 6, including the tolerance range therefor, must be determined empirically in dependence upon the design of the friction spinning apparatus. As to the design of the friction spinning apparatus, there should be taken into account for such control adjustment, among other things, for example, the diameter of the drums or rolls 4 and 24, the surface roughness of these drums or rolls 4 and 24, the quantity of air drawn in by the suction operation and so forth. As to the choice between performance or sequence of performance of the three abovementioned possible operational steps, if two or three of these operational steps are combined, such must be determined empirically; for example, the position of the suction nozzle 6 may be adjusted first and thereafter the width of the gap or nip F. If the yarn tension falls below the tension tolerance or tolerance range, then the width of the nip of gap F is reduced and/or the suction nozzle 6 is shifted in the direction of movement indicated by the arrow E in FIG. 3A. Conversely, if the yarn tension increases above the tension tolerance or tolerance range, then the two previously mentioned steps are carried out in the reverse sequence. By way of completeness, it is here mentioned that the yarn tension measured by the yarn tension measuring device 39 can be appropriately indicated at a suitable display or indicator device 100 (FIG. 2) and on the basis of which the yarn tension then can be altered by manually initiating the aforedescribed yarn tension correction measures. The control unit 41 shown for the friction spinning apparatus of FIGS. 1 to 3B is designed as an individual unit for each so-called spinning position or location (a plurality of spinning positions make up a spinning machine). It will be clear, however, that a solution of this type is expensive and is not absolutely necessary in view of the tension variations which occur slowly as a rule. It is therefore known from the rotor open-end spinning technique that so-called travelling devices or robots carry out checking and operating functions on respective spinning units, so that an optimalization can be achieved as regards costs and frequency of the operations to be performed per spinning position or location. It is therefore clear and should be so understood that a range of modifications can be provided in connection with travelling devices or robots, for example, all adjusting or positioning motors or the like required for adjusting the elements can be provided per spinning position, and only the yarn tension measuring equipment and control is allocated to the travelling device or robot; this represents the simplest solution mechanically. As another variant, a travelling device or robot can measure the yarn tension and indicate it by display means, such as the aforedescribed display or indicator device 100, and the elements to be adjusted in order to change the tension are operated manually until the tension again lies in the given tolerance range. A further application of the yarn tension measurement lies in the simple monitoring of the spinning position or location by means of the yarn tension measuring step or operation, i.e. that none of the aforedescribed measures to adjust the yarn tension are carried out, and on the basis of the given yarn tension tolerances a decision is made to stop the spinning unit in order to deal with the corresponding defect. It will therefore be clear that the inventive concept of using the yarn tension to maintain the spinning apparatus on a yarn quality level corresponding to the desired yarn quality, is not limited to the illustrated and described examples. 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,
To control the yarn quality of a yarn produced by a textile machine, for instance a friction spinning apparatus, there is provided at the end of the friction spinning operation, however, forwardly of the pair of withdrawal rolls for the outfeed of the produced yarn, a yarn tension measuring device. Upon deviating from or falling outside of a predeterminate yarn tension tolerance value or range the yarn tension measuring device controls operation of the friction spinning apparatus such that, as required, there is accomplished an appropriate increase or decrease of the yarn tension of the yarn produced by the friction spinning apparatus. Alteration of the yarn tension can be acheived, for instance, by acting upon the drive for one of the friction spinning elements, to control the rotational speed thereof, or by selectively positioning the suction nozzle of a friction spinning element, or by controlling the size of the nip between coacting friction spinning elements, or selected combinations of such measures.
3
[0001] This application claims priority to prior Japanese application JP 2005-41003, the disclosure of which is incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] This invention relates to a connector connectable selectively to two types of cards different in width. [0003] For example, a card called an express card is used as an object to be connected to the connector. The express card is produced in accordance with a card standard defined by PCMCIA (Personal Computer Memory Card International Association) and has two types including a narrow card/34 module and a wide card/54 module. Therefore, a connector used for connection of the express card is desired to be connectable to both of the two types of cards. [0004] For example, a connector of the type is disclosed in Japanese Unexamined Patent Application Publication (JP-A) No. 2004-318511 and has a housing adapted to receive a card to be inserted therein. The housing has a left insertion space and a right insertion space. Between the left and the right insertion spaces, a particular mechanism is disposed for guiding the narrow card to the left insertion space or the right insertion space. The mechanism has a rotary member rotated when it is pushed by the card. Thus, the narrow card is guided by the mechanism to one of the left and the right insertion spaces to be inserted therein. On the other hand, the wide card is inserted into a wide space as a combination of the left and the right insertion spaces. [0005] As described above, the above-mentioned connector is adapted to connect each of two types of cards different in width. However, since the narrow card is guided by the particular mechanism having the rotary member to the left or the right insertion space, the card may not smoothly be guided to a predetermined connecting portion. SUMMARY OF THE INVENTION [0006] It is therefore an object of this invention to provide a connector in which not only a wide card but also a narrow card is smoothly guided to a predetermined connecting position. [0007] It is another object of this invention to provide a connector reduced in size. [0008] It is still another object of this invention to provide a connector in which a card is smoothly ejected. [0009] It is yet another object of this invention to provide a connector which is capable of saving a space. [0010] Other objects of the present invention will become clear as the description proceeds. [0011] According to an aspect of the present invention, there is provided a connector adapted to be selectively connected to two types of cards inserted towards an insertion direction and different from each other in width thereof, the connector comprising a housing defining a guide space and having a guide portion for guiding an insertion of a selected one of the cards, the guide portion extending in the guide space in a particular direction intersecting the insertion direction, and an eject mechanism for moving the selected one towards a removing direction opposite to the first direction, the eject mechanism comprising an eject member to be engaged with the selected one and moved together with the selected one, an operating member for moving the eject member towards the removing direction, and a rotary member having a rotation center and rotatable around the rotation center to transmit operation of the operating member to the eject member, the rotation center being disposed in the guide space. BRIEF DESCRIPTION OF THE DRAWING [0012] FIG. 1A is a schematic view of a characteristic part of a card connector according to an embodiment of this invention; [0013] FIG. 1B is a schematic view of a characteristic part of a modification of the card connector illustrated in FIG. 1A ; [0014] FIG. 2A is a top rear perspective view of a first card; [0015] FIG. 2B is a bottom rear perspective view of the first card; [0016] FIG. 2C is a bottom front perspective view of the first card; [0017] FIG. 3A is a top rear perspective view of a second card; [0018] FIG. 3B is a bottom rear perspective view of the second card; [0019] FIG. 3C is a bottom front perspective view of the second card; [0020] FIG. 4A is a front view of the second card; [0021] FIG. 4B is a plan view of the second card; [0022] FIG. 4C is a rear view of the second card; [0023] FIG. 4D is a left side view of the second card; [0024] FIG. 4E is a right side view of the second card; [0025] FIG. 4F is a bottom view of the second card; [0026] FIG. 5 is a bottom view of a characteristic part of the card connector in FIG. 1A in a first stage of insertion of the first card; [0027] FIG. 6 is a bottom view similar to FIG. 5 in a second stage; [0028] FIG. 7 is a bottom view similar to FIG. 5 in a third stage; [0029] FIG. 8 is a bottom view similar to FIG. 5 in a fourth stage; [0030] FIG. 9 is a bottom view similar to FIG. 5 in a fifth stage; [0031] FIG. 10 is a bottom view similar to FIG. 5 in a sixth stage; [0032] FIG. 11 is a bottom view showing a path of the first card in the card connector illustrated in FIG. 1A ; [0033] FIG. 12 is a perspective view of the card connector in FIG. 1A as seen from the side of a first eject bar; [0034] FIG. 13 is a perspective view similar to FIG. 12 with an inner structure seen through; [0035] FIG. 14A is a perspective view of an eject mechanism of the card connector in FIG. 1A as seen in one direction; [0036] FIG. 14B is a perspective view similar to FIG. 14A as seen in another direction; [0037] FIG. 14C is an enlarged view of a rectangular part X in FIG. 14B ; [0038] FIG. 15A is a plan view of the card connector in FIG. 1A when a second card is fitted thereto; [0039] FIG. 15B is a plan view similar to FIG. 15A when the second card is ejected therefrom; [0040] FIG. 16A is a plan view of the second card and the eject mechanism in an ejected state; [0041] FIG. 16B is an enlarged view of a rectangular part Y in FIG. 16A ; [0042] FIG. 17 is a bottom view of the eject mechanism in the ejected state; [0043] FIG. 18 is a bottom view of a characteristic part of the card connector in FIG. 1A in a first stage of insertion of the first card, with a second eject bar faced to the first card; [0044] FIG. 19 is a bottom view similar to FIG. 18 in a second stage; [0045] FIG. 20 is a bottom view similar to FIG. 18 in a third stage; [0046] FIG. 21 is a bottom view similar to FIG. 18 in a fourth stage; [0047] FIG. 22 is a bottom view similar to FIG. 18 in a fifth stage; [0048] FIG. 23 is a bottom view similar to FIG. 18 in a sixth stage; [0049] FIG. 24 is a bottom view similar to FIG. 18 in a seventh stage; and [0050] FIG. 25 is a bottom view similar to FIG. 18 in an eighth stage. DESCRIPTION OF THE PREFERRED EMBODIMENTS [0051] Referring to FIG. 1A , description will be made of a card connector (hereinafter simply be referred to as a “connector”) according to an embodiment of this invention. [0052] As will be understood from the following description, the connector depicted at 1 in the figure uses a rotary lever mechanism and has a rectangular housing 2 . The housing 2 has a rectangular cutout portion 2 a formed at a right upper corner thereof, a guide space 2 b formed under the cutout portion 2 a to guide a first card, and a first guide wall 2 c and a first slide guide 2 d which are formed on the right side of the guide space 2 b . In parallel to the first slide guide 2 d , a first eject bar 3 is arranged to be slidable. The first eject bar 3 has an operation button 3 a. [0053] The housing 2 is provided with a second guide wall 2 e and a second slide guide 2 f which are formed on its right side surface adjacent to the cutout portion 2 a . In parallel to the second slide guide 2 f , a second eject bar 4 is arranged to be slidable. The second eject bar 4 has an end portion 4 a and an eject portion 4 b protruding from the end portion 4 a in a direction perpendicular thereto. [0054] In the guide space 2 b , a shaft 2 g is disposed and supports a rotary lever 5 fitted over the shaft 2 g . The first eject bar 3 is engaged with one end of the rotary lever 5 . The second eject bar 4 is engaged with the other end of the rotary lever 5 . Since the rotary lever 5 is disposed in the guide space 2 b , it is possible to arrange parts or components of the connector in the cutout portion 2 a . Thus, the cutout portion 2 a can effectively used to achieve a space-saving effect. [0055] Next, description will be made of an eject operation when a first card 11 (see FIGS. 2A to 2 C) or a second card 21 (see FIG. 3 ) is fitted to the connector 1 . [0056] First, it is assumed that the first card 11 (not shown) is inserted into a left side of the housing 2 . When the operation button 3 a is pushed in an insertion direction or a first direction A 1 , the rotary lever 5 is rotated counterclockwise around the shaft 2 g . Then, the second eject bar 4 slides in an opposite direction A 1 ′ opposite to the first direction A 1 so that the eject portion 4 b pushes a front end 11 a of the first card 11 . As a consequence, the first card 11 is ejected from the connector 1 . [0057] Next, it is assumed that the second card 21 is inserted into the housing 2 . When the operation button 3 a is pushed, the eject portion 4 b pushes a front end 21 a of the second card 21 in the manner similar to that described in connection with the first card 11 . As a consequence, the second card 21 is ejected from the connector 1 . [0058] An operation of inserting the first or the second card 11 or 21 will be described later. [0059] The connector 1 in FIG. 1A uses the rotary lever mechanism. Alternatively, a gear mechanism may be used instead as illustrated in FIG. 1B . Specifically, in the connector using the gear mechanism, each of the first and the second eject bar 3 and 4 is provided with a rack (not shown) which is engaged with a spur gear disposed between the first and the second eject bars 3 and 4 . [0060] Referring to FIGS. 2A to 2 C, the first card 11 will be described. [0061] The first card 11 is an express card/34 module and has a rectangular shape. The first card 11 has a pair of narrow grooves 11 b formed on longitudinal opposite sides of a top surface thereof and extending in a longitudinal direction (insert/eject direction). The first card 11 has a pair of wide grooves 11 c 1 formed on longitudinal opposite sides of a bottom surface thereof in the vicinity of the front end 11 a . Furthermore, the first card 11 has a pair of narrow grooves 11 c 2 continued from the wide grooves 11 c 1 , respectively. The first card 11 further has, adjacent to each of the wide grooves 11 c 1 , a corner portion 11 d , a tapered portion 11 e , and a parallel surface 11 f . Each of the corner portions 11 d , the tapered portions 11 e , and the parallel surfaces 11 f will be called here a guided portion. [0062] Referring to FIGS. 3A to 3 C and 4 A to 4 F, the second card 21 will be described. [0063] The second card 21 is an express card/54 module. The second card 21 has a shape such that a small rectangle around an upper right corner of a large rectangle is cut away and has a cutout portion 21 b . The second card 21 has a pair of narrow grooves 21 c formed on longitudinal opposite sides of a top surface thereof. The second card 21 has a pair of wide grooves 21 d 1 formed on longitudinal opposite sides of a bottom surface thereof in the vicinity of the front end 21 a . The second card 21 is provided with a pair of narrow grooves 21 d 2 , a pair of generally triangular grooves 21 d 3 , and a pair of narrow grooves 21 d 4 successively formed continuously from the grooves 21 d 1 , respectively. Since the second card 21 has the generally triangular grooves 21 d 3 , the second card 21 is not brought into contact with the rotary lever 5 , the shaft 2 g , and the second eject bar 4 as an eject mechanism when the second card 21 is fitted to the connector 1 . [0064] Next referring to FIGS. 5 to 11 , description will be made of an insertion process of the first card 11 . [0065] In a first stage illustrated in FIG. 5 , the first card 11 is started to be inserted into the housing 2 in the first direction A 1 . When insertion of the first card 11 proceeds to reach a second stage illustrated in FIG. 6 , the corner portions 11 d of the first card 11 are contacted with an inclined guide surface 2 b 1 of the guide space 2 b of the housing 2 . The inclined guide surface 2 b 1 is inclined with respect to the first direction A 1 . [0066] When the insertion of the first card 11 further proceeds, the first card 11 is moved in the first direction A 1 and a particular direction or a second direction A 2 perpendicular to the first direction A 1 . Then, a third stage illustrated in FIG. 7 is reached. In the third stage, the corner portions 11 d of the first card 11 are started to be guided by a parallel guide surface 2 b 2 of the guide space 2 b of the housing 2 . The parallel guide surface 2 b 2 is parallel to the firs direction A 1 . [0067] When the insertion of the first card 11 still further proceeds, the first card 11 is moved only in the first direction A 1 . Then, a fourth stage illustrated in FIG. 8 is reached. In the fourth stage, the tapered portion 11 e of the first card 11 is started to be guided by an inclined guide surface 2 b 3 of the guide space 2 b of the housing 2 . The inclined guide surface 2 b 3 is also inclined with respect to the first direction. [0068] When the insertion of the first card 11 yet further proceeds, the first card 11 is moved in the first and the second directions A 1 and A 2 . Then, a fifth stage illustrated in FIG. 9 is reached. In the fifth stage, the tapered portion 11 e of the first card 11 is started to be guided by a parallel guide surface 2 b 4 of the guide space 2 b of the housing 2 . [0069] When the insertion of the card 11 further proceeds, the first card 11 is moved only in the first direction A 1 . Then, a sixth stage illustrated in FIG. 10 is reached. In the sixth stage, a left side surface of the groove 11 c 1 on the left side of the bottom surface of the first card 11 is guided by the parallel guide surface 2 b 4 of the guide space 2 b of the housing 2 . In FIG. 11 , an area between two broken lines 7 a and 7 b shows a path 2 b 5 of the first card 11 in the connector 1 . A combination of the inclined guide surfaces 2 b 1 and 2 b 3 will be called an inclined surface. A combination of the inclined guide surfaces 2 b 1 and 2 b 3 and the parallel guide surfaces 2 b 2 and 2 b 4 will be referred to as a guide surface. [0070] Referring to FIGS. 12 to 17 , the connector 1 will be described in detail. [0071] The housing 2 has an insertion slot 2 h through which the card is inserted into the housing 2 . The rotary lever 5 has a hole 5 a fitted over the shaft 2 g of the housing 2 . The rotary lever 5 has one end 5 b engaged with a right-angled portion 3 b formed at an end of the first eject bar 3 . The rotary lever 5 has the other end 5 c provided with a hole 5 c 1 engaged with a protruding portion 4 d formed in the vicinity of a curved rear end 4 c of the second eject bar 4 . The rear end 4 c of a smooth shape is positioned nearer to the insertion slot 2 h than engaging portions 4 d and 5 c 1 of the second eject bar 4 and the rotary lever 5 . The shaft 2 g of the housing 2 is disposed in the guide space 2 b . Since the rear end 4 c (see FIG. 14 ) of the second eject bar 4 has an R shape (smooth shape), the rear end 4 c is brought into contact with an end of the card to smoothly guide the card to a predetermined fitting position. The rear end 4 c will be referred to as a contact portion. [0072] The second eject bar 4 further has an extended portion 4 e extended from the rear end 4 c . The extended portion 4 e has an end 4 f displaced from the rear end 4 c towards the insertion direction or the first direction A 1 . [0073] Referring to FIGS. 18 to 25 in addition, description will be made of the insertion process of the first card 11 more in detail. [0074] In a first stage illustrated in FIG. 18 , the first card 11 is started to be inserted into the housing 2 . In the first stage, the second eject bar 4 is faced to the first card 11 . [0075] When the insertion of the first card 11 slightly proceeds to reach a second stage illustrated in FIG. 19 , the first card 11 is closely adjacent to the second eject bar 4 . Further, the corner portions 11 d of the first card 11 are brought into contact with the inclined guide surface 1 b 1 to be guided. [0076] When the insertion of the first card 11 further proceeds, a third stage illustrated in FIG. 20 is reached. In the third stage, the front end 11 a of the first card 11 is brought into contact with the curved rear end 4 c of the second eject bar 4 . [0077] When the insertion of the first card 11 further proceeds, a fourth stage illustrated in FIG. 21 is reached. In the fourth stage, the front end 11 a of the first card 11 pushed the rear end 4 c of the second eject bar 4 to slide the second eject bar 4 . At this time, the parallel surface 11 f of the first card 11 is guided by the parallel guide surface 2 b 2 of the guide space 2 b. [0078] When the insertion of the first card 11 further proceeds, a fifth stage illustrated in FIG. 22 is reached. In the fifth stage, the front end 11 a of the first card 11 further pushes the rear end 4 c of the second eject bar 4 to further slide the second eject bar 4 . In addition, the tapered portion 11 e of the first card 11 slides along the inclined guide surface 2 b 3 of the guide space 2 b of the housing 2 . [0079] When the insertion of the first card 11 further proceeds, a sixth stage illustrated in FIG. 23 is reached. In the sixth stage, the second eject bar 4 slides to a final position of its stroke. The tapered portion 11 e further slides along the inclined guide surface 2 b 3 . [0080] When the insertion of the first card 11 further proceeds, a seventh stage illustrated in FIG. 24 is reached. In the seventh stage, the tapered portion 11 e at a left corner of the groove 11 c 1 on the left side of the bottom surface of the first card 11 is started to be guided by the parallel guide surface 2 b 4 of the guide space 2 b of the housing 2 . [0081] When the insertion of the first card 11 further proceeds, an eighth stage illustrated in FIG. 25 is reached. In the eighth stage, the left side surface of the groove 11 c 1 on the left side of the bottom surface of the first card 11 is guided by the parallel guide surface 2 b 4 of the guide space 2 b of the housing 2 . [0082] In case where the first card 11 is inserted into a left half of the housing 2 from the outset, the front end 11 a of the first card 11 pushes the eject portion 4 b of the second eject bar 4 without contacting the inclined guide surface 2 b 1 of the housing 2 . Therefore, the second eject bar 4 slides in the first direction A 1 in FIG. 1A . The rotary lever 5 is rotated clockwise around the shaft 2 g . The first eject bar 3 slides in the opposite direction A 1 ′ opposite to the first direction A 1 . [0083] While the present invention has thus far been described in connection with the preferred embodiment thereof, it will readily be possible for those skilled in the art to put this invention into practice in various other manners. For example, although the description is made about a case where express cards are selectively used one at a time, the other cards can be used in place of the express cards.
In a connector adapted to be selectively connected to two types of cards inserted towards an insertion direction and different from each other in width thereof, a housing defines a guide space and has a guide portion for guiding an insertion of a selected one of the cards. The guide portion extends in the guide space in a particular direction intersecting the insertion direction. An eject mechanism is provided for moving the selected one towards a removing direction opposite to the first direction. The eject mechanism includes an eject member to be engaged with the selected one and moved together with the selected one, an operating member for moving the eject member towards the removing direction, and a rotary member having a rotation center and rotatable around the rotation center to transmit operation of the operating member to the eject member. The rotation center is disposed in the guide space.
8
CROSS-REFERENCE TO RELATED APPLICATION [0001] This application is a continuation of U.S. patent application Ser No. 13/402,090, filed on Feb. 22, 2012. The entire contents of U.S. patent application Ser. No. 13/402,090 is incorporated herein by reference. BACKGROUND [0002] 1. Field of the Invention [0003] The present invention generally relates to a system and method of emanating a sound from a vehicle. More specifically, the present invention relates to a system and method of emanating a sound from a vehicle based on intent to move the vehicle. [0004] 2. Background Information [0005] Electric and hybrid vehicles are becoming increasingly popular for reasons such as rising fuel costs and environmental concerns. A secondary advantage of the shift toward widespread use of electric vehicles is the reduction of ambient noise which is emanated by an internal combustion engine (ICE) used in most vehicles today. With 100% electric power running the vehicle, generally only tire noise and some slight electric motor noise is generated during operation of fully electric vehicles. Although this greatly reduces noise pollution, this lack of noise can make it difficult for pedestrians to detect the presence of a vehicle. That is, pedestrians are highly reliant on ICE noise to detect the presence of vehicles, especially when the pedestrian is hearing or visually impaired. [0006] One attempted solution to enable better pedestrian detection of the vehicle is to generate a vehicle sound for pedestrians (VSP). For example, a vehicle can be controlled to emit a synthetic ICE sound during operation of the vehicle, thereby enabling detection of the electric vehicle in the same way as ICE vehicles. Other attempts to generate sounds can include, for example, generating an unpleasant horn-like sound at an ambient noise frequency, or generating a sound having peaks at an ambient noise frequency. SUMMARY [0007] It has been discovered that it is desirable to control the vehicle to emit a VSP at appropriate times to warn pedestrians and to refrain from emitting a VSP at unnecessary times. For example, if a vehicle is idling in a driveway in the morning to warm up the passenger cabin on a cold day, the VSP being emitted may annoy neighbors trying to sleep. Also, if a driver is stopped in traffic on a hot day with the vehicle windows down, the driver and drivers of other vehicles may become annoyed hearing the VSP through the open windows. Furthermore, since the National Highway Traffic Safety Administration (NHTSA) may prohibit VSP systems from including turn off switches, a driver may be unable to temporarily disable the VSP system during times when VSP emission is unnecessary. [0008] In view of the state of the known technology, one aspect of the present invention provides a method of emanating a sound from a vehicle comprising detecting a speed of the vehicle, and emanating a speed sound, including emanating a sound profile and changing at least one of a sound pressure level and a pitch of the sound profile in relation to the speed of the vehicle changing. The method further comprises ceasing emanation of the speed sound upon the speed of the vehicle increasing from below a first threshold to above the first threshold, and resuming emanation of the speed sound upon the speed of the vehicle decreasing from above a second threshold to below the second threshold, the second threshold being less than the first threshold. BRIEF DESCRIPTION OF THE DRAWINGS [0009] Referring now to the attached drawings which form a part of this original disclosure: [0010] FIG. 1 is a schematic view illustrating an example of components of a system for emanating a sound from a vehicle according to a disclosed embodiment; [0011] FIGS. 2A and 2B illustrate an exemplary process performed by the system shown in FIG. 1 to emanate the sound from the vehicle according to disclosed embodiments; [0012] FIG. 3 is an exemplary graphical representation of the process shown in FIGS. 2A and 2B during vehicle forward movement at low speed; [0013] FIG. 4 is a variation to the graphical representation shown in FIG. 3 illustrating exemplary operations that can be performed when the vehicle movement state does not indicate an intent to move the vehicle at or about the time that the vehicle comes to a stop; [0014] FIG. 5 is a variation to the graphical representation shown in FIG. 3 illustrating exemplary operations that can be performed when the speed of the vehicle reaches a predetermined speed; and [0015] FIG. 6 is an exemplary graphical representation of the process shown in FIGS. 2A and 2B during vehicle reverse movement. DETAILED DESCRIPTION OF EMBODIMENTS [0016] Selected embodiments will now be explained with reference to the drawings. It will be apparent to those skilled in the art from this disclosure that the following descriptions of the embodiments are provided for illustration only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. [0017] Referring initially to FIG. 1 , a vehicle sound emanating system 10 for use in a vehicle 12 is illustrated in accordance with an embodiment of the present invention. The vehicle 12 can be an electric or hybrid vehicle as understood in the art, and can be any type of vehicle such as a car, truck, van, SUV and so on. The vehicle sound emanating system 10 includes a controller 14 and a vehicle sound production (VSP) module 16 that generates a sound that can serve as an audible alert as discussed in more detail below. As understood by one skilled in the art, the controller 14 preferably includes a microcomputer with a control program that controls the vehicle sound emanating system 10 as discussed herein. The controller 14 can also include other conventional components such as an input interface circuit, an output interface circuit, and storage devices such as a ROM (Read Only Memory) device and a RAM (Random Access Memory) device. The RAM and ROM store processing results and control programs that are run by the controller 14 . The controller 14 is operatively coupled to the components of the vehicle sound emanating system 10 , and to the components of the vehicle 12 as appropriate, in a conventional manner. It will be apparent to those skilled in the art from this disclosure that the precise structure and algorithms for the controller 14 can be any combination of hardware and software that will carry out the functions of the present invention. [0018] The controller 14 receives signals from the start switch 18 , accelerator position sensor 20 , speed sensor 22 , brake state detector 24 and transmission state detector 26 , and controls the VSP module 16 based on those signals as discussed in more detail below. The vehicle sound emanating system 10 can further include a VSP switch 28 that provides on/off signals to the VSP module 16 that enables a user to turn the VSP module 16 on and off. The VSP module 16 provides signals to at least one audio component 30 , such as a speaker arrangement, to cause the audio component 30 to generate an audible alert as discussed in more detail below. The terms “sound” and “audible alert” can be used interchangeably herein. [0019] Specifically, the controller 14 controls the VSP module 16 to emanate a sound from the vehicle 12 according to the exemplary process as shown in FIGS. 2A and 2B and in the graphs as shown in FIGS. 3-6 . For purposes of the embodiments described herein, the terms “continuously,” “continuous” and any variations or synonyms thereof as used to modify terms such as “sound,” “signal,” “emanating”, “emanate,” “emit” and so on refer to the outputting or emanation of a sound profile, sound or signal in a manner that is perceptible as continuous (i.e., without pauses or gaps) by a human having normal hearing. In other words, for example, “continuously emanating a sound” refers to the continuous emanation of a sound, as well as the emanation of sound profile with pauses, gaps, dead spots, etc., in a manner such that the sound profile is perceived as a continuous sound profile by a human having normal hearing even though the actual emanation is not in fact continuous. [0020] As shown in FIGS. 2A and 2B , the process begins when the controller 14 determines based on signals from the start switch 18 (e.g., an ignition or starter) that the vehicle 12 is started from an “off” state to an “on” or running state in step 100 . During the vehicle starting period, the controller 14 controls the VSP module 16 to refrain from emanating an audible alert sound from the audio component 30 in step 110 . The vehicle starting period is shown as the period between times t 0 and t 1 in, for example, FIG. 3 . FIG. 3 is an exemplary graphical representation of the process shown in FIGS. 2A and 2B during vehicle forward movement at low speed as discussed in more detail below. [0021] The controller 14 then determines in step 120 whether a vehicle movement state indicates intent to move the vehicle 12 from a stationary state. The controller 14 can determine that the vehicle 12 is in a stationary state when, for example, the transmission state detector 26 indicates that the vehicle transmission is in a park position or in a neutral position, or the brake state detector 24 indicates the emergency brake is on. Naturally, the transmission can be an automatic transmission or a manual transmission as understood in the art. The controller 14 can also determine that the vehicle 12 is in a stationary state when, for example, the speed sensor 22 indicates that the vehicle 12 is not moving, regardless of the positions of the transmission, the brake and the emergency brake. When the vehicle 12 is in the stationary state, such as during the period between t 1 and t 2 in FIG. 3 , the controller 14 continues to receive signals from the brake state detector 24 and the transmission state detector 26 . The controller 14 can detect the vehicle movement state from, for example, at least a transmission state and a brake state of the vehicle 12 . The controller 12 thus determines in step 120 whether the vehicle movement state indicates intent to move the vehicle 12 based on the transmission state and the brake state. If the brake has not been moved into the brake depressed state, the controller 14 controls the VSP module 16 to continue to refrain from emanating the sound. That is, the controller 14 controls the VSP module 16 to continue to refrain from emanating the sound in step 110 during a vehicle running state after the vehicle starting period and before a brake of the vehicle 12 is moved into a brake depressed state while the vehicle 12 is in a stationary state. In other words, the controller 14 controls the VSP module 16 to refrain from emanating the sound when the vehicle 12 is in the stationary state and the vehicle movement state fails to indicate intent to move the vehicle 12 . [0022] As can be appreciated from the above, the vehicle movement state indicates intent to maintain the vehicle stationary when the transmission state is a non-motive state and the brake state is a brake undepressed or released state. It should be noted that the terms undepressed or released can be used interchangeably. When the controller 14 determines in step 120 that, for example, the brake is moved into the brake depressed state (time t 2 in FIG. 3 ), the controller 14 determines that the vehicle movement state indicates intent to move the vehicle 12 from the stationary state. In this example, the vehicle movement state indicates intent to move the vehicle 12 when the transmission state is a non-motive state, such as a vehicle park position or a vehicle neutral position, and the brake state is a brake depressed state. Accordingly, processing continues to step 130 where the controller 14 controls the VSP module 16 to emanate an audible alert from the audio component 30 at a first sound pressure level while the vehicle 12 is in the stationary state. [0023] The controller 14 controls the VSP module 16 to continue emanating the audible alert from the audio component 30 while the controller 14 monitors the signals from the transmission state detector 26 in step 140 . When the controller 14 determines based on the signals from the transmission state detector 26 that the transmission has not yet been moved to a motive state, the processing returns to step 120 to confirm that the vehicle movement state still indicates an intent to move. If the vehicle movement state still indicates an intent to move, the controller 14 controls the VSP module 16 to continue emanating the audible alert from the audio component 30 in step 130 and proceeds to step 140 . If the vehicle movement state fails to indicate intent to move, the controller 14 controls the VSP module 16 to refrain from emanating the audible alert from the audio component 30 in step 110 and repeats as discussed above. [0024] However, when the controller 14 determines based on the signals from the transmission state detector 26 that the transmission has been moved to a motive state (time t 3 in FIG. 3 ), the processing continues to step 150 . It should be noted that when the transmission state is a motive state and the brake state is any brake state, the vehicle movement state indicates intent to move the vehicle. [0025] In step 150 , the controller 14 determines whether the motive state is a vehicle forward movement position (e.g., a drive transmission position) or a vehicle reverse movement position (i.e., a reverse transmission position). As mentioned above, the transmission can be an automatic or manual transmission. Thus, for a manual transmission, the forward movement position could be any of the forward gear positions such as first gear, second gear, third gear and so on. If the controller 14 determines that the motive state is a vehicle forward movement position, the processing continues to step 160 where the controller 14 monitors the accelerator position sensor 20 , the speed sensor 22 , or both, to determine whether the vehicle 12 has begun to move. During this time, the controller 14 can control the VSP module 16 to continue to emanate the sound from the audio component 30 at the first sound pressure level while the transmission state is the motive state (e.g., forward motive state) and the brake state is the brake depressed state. [0026] When the controller 14 determines in step 160 that the vehicle 12 is not moving, the controller 14 determines in step 170 whether the brake state is a brake released state. If the brake state is not a brake released state, the processing will return to step 140 as discussed above, and the controller 14 can control the VSP module 16 to continue to emanate the sound from the audio component 30 at the first sound pressure level. Assuming that the gear remains in the forward motive gear and the vehicle 12 is not moving, the processing will proceed through steps 140 , 150 and 160 as discussed above. The controller 14 will continue to monitor the brake state and repeat the steps as discussed above. When the controller 14 determines in step 170 that the brake is in a brake released state, the processing continues to step 180 . [0027] In step 180 , the controller 14 determines based on signals from the accelerator position sensor 20 whether the accelerator is in a depressed state. If the accelerator is not in a depressed state, the processing returns to step 170 and repeats as discussed above. That is, as long as the brake is in the brake released state, the processing will continue to step 180 . [0028] When the controller 14 determines in step 180 that the accelerator is in a depressed state and thus, the vehicle 12 will begin to move (time t 4 in FIG. 3 ), the controller 14 controls the VSP module 16 to emanate a take off sound from the audio component 30 in step 190 . For example, the controller 14 can control the VSP module 16 to emanate the take off sound at a second sound pressure level that is greater than the first sound pressure level upon first detecting that the brake state changes from the brake depressed state to the brake released state and then detecting that the accelerator state changes from a released state to a depressed state while the transmission state is the motive state and the vehicle 12 is in the stationary state (time t 4 in FIG. 3 ). [0029] After emitting the take off sound at the second sound pressure level for a predetermined period of time from when the accelerator state changes from the released state to the depressed state (time t 4 in FIG. 3 ), the controller 14 can control the VSP module 16 to decrease the sound. That is, in step 190 , the controller 14 can control the VSP module 16 to decrease the sound from the second sound pressure level to a decreased third sound pressure level that is below the second sound pressure level (time t 5 in FIG. 3 ). The third sound pressure level can be equal to or greater than the first sound pressure level. The processing then returns to step 160 . [0030] Since the accelerator was or still is in the depressed state, the controller 14 will determine in step 160 that the vehicle 12 is moving. Thus, the processing will continue to step 200 . In step 200 , the controller 14 can monitor the signals from the accelerator position sensor 20 , the signals from the speed sensor 22 , or both, to determine whether the vehicle 12 is being accelerated. If the controller 14 determines that the vehicle 12 is being accelerated, the processing continues to step 210 . In step 210 , the controller 14 determines based on the signals from the speed sensor 22 whether the speed of the vehicle 12 is not above a predetermined speed (a first prescribed speed). As long as the speed of the vehicle 12 is at or below a predetermined speed, the processing continues to step 220 and the controller 14 controls the VSP module 16 to increase the sound pressure level in relation to the acceleration (or speed) of the vehicle 12 . Therefore, as shown in FIG. 3 , the sound pressure level increases to a fourth sound pressure level while the vehicle 12 is being accelerated. The fourth sound pressure level can be less than the second sound pressure level as shown, or can be any suitable level. [0031] Thus, FIG. 3 illustrates operations that can occur when the vehicle 12 is traveling at a low speed, such as below 30 km/hr or any other suitable speed. In addition, the controller 14 can control the VSP module 16 to change a pitch of the sound in accordance with at least one of the position of the accelerator and the speed of the vehicle 12 . Furthermore, the controller 14 can control the VSP module 16 to pulse the sound as discussed above with regard to FIG. 6 at any time that the sound is being emitted, and can vary the cadence of the pulsing as desired, such as in accordance with acceleration (or speed) of the vehicle 12 . [0032] When the controller determines in step 200 that the vehicle 12 is no longer being accelerated and is not moving at a speed above the first predetermined speed (time t 6 in FIG. 3 ), the controller 14 can control the VSP module 16 to continue to emit the sound at the fourth sound pressure level. That is, if the controller 14 determines in step 200 that the vehicle 12 is not being accelerated, the controller 14 can monitor signals from the brake state detector 24 , signals from the speed sensor 22 , or both, in step 240 to determine whether the vehicle 12 is decelerating. If the controller 14 determines in step 240 that the vehicle 12 is not decelerating, the controller 14 can proceed to step 250 to determine whether the vehicle 12 is stopped based on, for example, the signals from the vehicle speed sensor 22 . If the vehicle 12 is not stopped, the processing can return to step 160 and repeat as discussed above. [0033] Therefore, although not shown explicitly in FIG. 3 , the controller 14 can continue to monitor the position of the accelerator, the signals from the speed sensor 22 , or both, in step 200 to determine whether the vehicle 12 is again accelerated. If the vehicle 12 is again being accelerated, the processing can return to step 210 to determine whether the vehicle 12 is not traveling above the predetermined speed. If the vehicle 12 is still not traveling above the predetermined speed, the processing continues to step 220 and the controller 14 can control the VSP module 16 to increase the pressure level of the emitted sound in relation to the acceleration of the vehicle 12 . [0034] The controller 14 also continues to monitor whether the vehicle 12 is being decelerated. That is, if the controller 14 determines in step 200 that the vehicle 12 is not being accelerated, the controller 14 can monitor signals from the brake state detector 24 , signals from the speed sensor 22 , or both, in step 240 . If the controller 14 determines in step 240 that the vehicle 12 is decelerating, the controller 14 can determine in step 260 whether the speed of the vehicle 12 is below a second prescribed speed. Presumably, for this example where the vehicle 12 is traveling at a low speed, such as below 30 km/hr or any other suitable speed, the speed of the vehicle 12 will be below the second prescribed speed. The second prescribed speed can be equal to or about equal to the first prescribed speed (e.g., 30 km/hr, 25 km/hr or any other suitable speed). [0035] Accordingly, if the controller 14 determines in step 260 that the vehicle 12 is travelling below the second prescribed speed, the processing continues to step 270 . In step 270 , the controller 14 will control the VSP module 16 to gradually decrease the pressure level of the emitted sound from the fourth sound pressure level (time t 7 in FIG. 3 ). [0036] The controller 14 then determines in step 250 whether the vehicle 12 is stopped based on, for example, the signals from the vehicle speed sensor 22 . As discussed above, if the vehicle 12 is not stopped, the processing can return to step 160 . Assuming that the vehicle 12 is moving (step 160 ), the vehicle 12 is not accelerating (step 200 ), the vehicle 12 is decelerating (step 240 ) and the speed of the vehicle 12 is below the second prescribed speed (step 260 ), the controller 14 can control the VSP module 16 to continue to decrease the pressure level of the emitted sound from the fourth sound pressure level (or increased pressure level) to the first sound pressure level or any other suitable pressure level in step 270 . The processing then can repeat as discussed above as long as the vehicle 12 is not stopped. [0037] When the controller 14 determines in step 250 that the vehicle 12 is stopped (time t 8 in FIG. 3 ), the processing returns to step 120 as discussed above. Thus, in step 120 , the controller 14 will determine whether the vehicle movement state indicates intent to move the vehicle 12 as discussed above. For example, the controller 14 will monitor signals from the brake state detector 24 and the transmission state detector 26 to determine whether the transmission has been moved to a non-motive state and the brake is in the depressed state, or the transmission remains in a motive state. If the controller 14 determines in step 120 that, for example, the transmission has not been moved to a non-motive state such as park or neutral (time t 9 in FIG. 3 ) and the brake is still in the depressed state, or the transmission remains in a motive state, the controller 14 will determine that the vehicle movement state still indicates intent to move the vehicle 12 . Accordingly, the controller 14 will control the VSP module 16 to continue to emit sound from the audio component 30 at the first sound pressure level in step 130 . If the controller 14 determines in step 140 that the transmission is still in the motive gear, the processing proceeds to step 150 and repeats as discussed above. [0038] Furthermore, when the controller 14 determines in step 140 that the transmission is in the non-motive state, the controller 14 will determine in step 120 whether the vehicle movement state still indicates intent to move the vehicle 12 in the manner as discussed above. However, when the controller 14 determines in step 140 that the transmission is in the non-motive state and then determines in step 120 the brake is in the released state, the controller 14 will thus determine in step 120 that the vehicle movement state does not indicate intent to move the vehicle 12 . Therefore, the controller 14 will control the VSP module 16 in step 110 to discontinue emitting the sound (time t 10 in FIG. 3 ). In other words, the controller 14 controls the VSP module 16 to cease emanating the sound when the vehicle returns to the stationary state after moving, the transmission state enters a non-motive state and the brake state enters a released state, in which event the vehicle movement state indicates intent to maintain the vehicle 12 stationary. [0039] The process then repeats as discussed above. Naturally, if the vehicle 12 is turned off, the process repeats at step 100 when the vehicle 12 is turned on again. [0040] Also, instead of the controller 14 controlling the VSP module 16 in step 220 to increase the sound pressure level, the controller 14 can instead control the VSP module 16 to maintain the sound pressure level at the third sound pressure level as shown in broken line in FIG. 3 , or at any other suitable sound pressure level, during vehicle acceleration as long as the speed of the vehicle 12 is at or below a predetermined speed. As stated above, the third sound pressure level can be at or above the first sound pressure level, but is below the second sound pressure level of the take off sound. The processing otherwise is performed as described above with regard to FIG. 3 . Thus, when the processing continues to step 270 , the controller 14 controls the VSP module 16 to gradually decrease the pressure level of the emitted sound from the third sound pressure level to the first sound pressure level (similar to time t 7 in FIG. 3 ). Naturally, if the third pressure level is the same as the first pressure level, no such decrease needs to be performed, and the processing can continue as discussed above with regard to FIG. 3 . [0041] FIG. 4 is identical to FIG. 3 , except that FIG. 4 illustrates an example of operations that can be performed when the controller 14 determines in step 120 that the vehicle movement state does not indicate intent to move the vehicle 12 when the vehicle 12 comes to a stop at time t 8 . That is, in step 140 of the flowchart in FIGS. 2A and 2B , the controller 14 detects based on signals from the transmission state detector 26 that the transmission has been moved to a non-motive state such as park or neutral at or proximate to the time that the vehicle 12 has come to a stop. The controller 14 also detects in step 120 based on signals from the brake state detector 24 that the brake is in the released state at or proximate to the time that the vehicle 12 has come to a stop and the transmission has been moved to the non-motive state. [0042] Accordingly, as shown in FIG. 4 , the controller 14 will control the VSP module 16 in step 100 to discontinue emitting the sound at or proximate to time t 8 in FIG. 4 . The processing then repeats as discussed above. Therefore, the controller 14 controls the VSP module 16 to refrain from emanating the sound (an audible alert) from the audio component 30 in step 110 . However, once the controller 14 determines in step 120 that the vehicle movement state indicates intent to move the vehicle 12 , the controller 14 controls the VSP module 16 to emanate the sound at the first sound pressure level (time t 9 in FIG. 4 ) and performs the operations as discussed above. Accordingly, the times indicated at t 10 and t 11 in FIG. 4 correspond to times t 2 and t 3 , respectively, as shown in FIGS. 3 and 4 . [0043] Furthermore, as with the operations in FIG. 3 , the controller 14 can control the VSP module 16 to maintain the sound pressure level at the third sound pressure level as shown in broken line in FIG. 4 , or at any other suitable sound pressure level, during vehicle acceleration as long as the speed of the vehicle 12 is at or below a predetermined speed. The processing otherwise is performed as described above with regard to FIG. 4 . Thus, when the processing continues to step 270 , the controller 14 controls the VSP module 16 to gradually decrease the pressure level of the emitted sound from the third sound pressure level to the first sound pressure level (similar to time t 7 in FIG. 4 ). Naturally, if the third pressure level is the same as the first pressure level, no such decrease needs to be performed, and the processing can continue as discussed above with regard to FIG. 4 . [0044] As discussed above with regard to step 210 shown in the flowchart of FIGS. 2A and 2B , the controller 14 determines in step 210 whether the speed of the vehicle 12 is below the first prescribed speed. FIG. 5 illustrates an exemplary graph of operations that the controller 14 can perform when the speed of the vehicle 12 reaches the first prescribed speed. The graph shown in FIG. 5 from times t 0 through t 6 generally corresponds to the graph shown in FIG. 3 from times t 0 through t 6 . However, in FIG. 5 , time t 6 indicates the sound pressure level when the vehicle 12 reaches the first prescribed speed. [0045] As shown in the flowchart of FIGS. 2A and 2B , when the controller 14 determines in step 210 that the speed of the vehicle 12 is above the first prescribed speed, the processing proceeds to step 230 . In this example, the first prescribed speed can be 30 km/hr or any other suitable speed as discussed above. That is, as understood in the art, when the vehicle 12 is traveling at or above 25 km/hr, the noise naturally produced by the vehicle 12 , such as road noise and so on, is sufficient enough to be detected by pedestrians, so the VSP sound is no longer needed at those speeds. [0046] In step 230 , the controller 14 controls the VSP module 16 to gradually decrease or fade out the sound pressure level of the emitted sound until time t 7 shown in FIG. 5 when the VSP module 16 ceases to emit the sound. The processing then returns to step 160 and repeats as discussed above. When the controller 14 determines in step 200 that the vehicle 12 is not accelerating, the processing continues to step 240 where the controller 14 determines whether the vehicle 12 is decelerating. If the vehicle 12 is decelerating, the processing continues to step 260 where the controller 14 determines whether the vehicle 12 continues to travel at or above the second prescribed speed. In this example, the second prescribed speed can be 25 km/hr or slightly below the first prescribed speed as discussed above. Naturally, the first and second prescribed speeds can be equal to each other or any suitable speeds. While the vehicle 12 is traveling at or above the second prescribed speed, the controller 14 controls the VSP module 16 in step 230 to continue to refrain from emitting the sound. [0047] As further shown in the example of FIG. 5 , the accelerator is released and the brake is pressed and enters the brake depressed state at time t 8 . Therefore, the speed of the vehicle 12 begins to decrease. When the controller 14 determines in step 260 that the speed of the vehicle 12 has dropped to below the second prescribed speed (time t 9 in FIG. 5 ), the controller 14 controls the VSP module 16 to gradually increase or fade in the sound pressure level of the emitted sound in step 270 until the VSP module 16 emits the sound at the fourth sound pressure level (or any other suitable sound pressure level) as discussed above. [0048] The processing thus continues to step 250 as discussed above. If the vehicle 12 is not stopped, the processing returns to step 160 and repeats. Since the controller 14 determines in step 240 that the vehicle 12 is decelerating because, for example, the brake is determined to be in the brake depressed state and thus the speed sensor 22 indicates that the vehicle speed is decreasing, the controller 14 controls the VSP module 16 to decrease the sound pressure level in step 270 (time t 10 in FIG. 5 ) to the first sound pressure level until the vehicle 12 is determined to be stopped in step 250 as discussed above. When the controller 14 determines in step 250 that the vehicle 12 is stopped (time t 11 in FIG. 5 ), the processing returns to step 120 where the controller 14 will determine whether the vehicle movement state indicates intent to move the vehicle 12 as discussed above. If the controller 14 determines in step 120 that the vehicle movement state still indicates intent to move the vehicle 12 , the controller 14 will control the VSP module 16 to continue to emit sound in step 130 . Furthermore, if the controller 14 determines in step 140 that the transmission has been moved to a non-motive state such as park or neutral (time t 12 in FIG. 5 ) and the brake is still in the depressed state, the controller 14 will return to step 120 and determine that the vehicle movement state still indicates intent to move the vehicle 12 . Accordingly, the controller 14 will control the VSP module 16 to continue to emit sound from the audio component 30 at the first sound pressure level in step 130 . However, when the controller 14 determines in step 140 that the transmission is in the non-motive state and determines in step 120 that the brake is in the released state, the controller 14 will determine that the vehicle movement state does not indicate intent to move the vehicle 12 . Therefore, the controller 14 will control the VSP module 16 in step 110 to discontinue emitting the sound (time t 13 in FIG. 5 ). [0049] The process then repeats as discussed above. Naturally, if the vehicle 12 is turned off, the process repeats at step 100 when the vehicle 12 is turned on again. [0050] Furthermore, as with the operations in FIGS. 3 and 4 , the controller 14 can control the VSP module 16 to maintain the sound pressure level at the third sound pressure level as shown in broken line in FIG. 5 , or at any other suitable sound pressure level, during vehicle acceleration as long as the speed of the vehicle 12 is at or below a predetermined speed (times t 5 through t 6 ). The processing otherwise is performed as described above with regard to FIG. 5 . Thus, in step 230 , the controller 14 controls the VSP module 16 to gradually decrease or fade out the sound pressure level of the emitted sound from the third sound pressure level until time t 7 shown in FIG. 5 when the VSP module 16 ceases to emit the sound. The processing then returns to step 160 and repeats as discussed above. When the controller 14 determines in step 260 that the speed of the vehicle 12 has dropped to below the second prescribed speed (time t 9 in FIG. 5 ), the controller 14 controls the VSP module 16 to gradually increase or fade in the sound pressure level of the emitted sound in step 270 until the VSP module 16 emits and maintains the sound at the third sound pressure level (or any other suitable sound pressure level) as discussed above. When the processing continues to step 270 , the controller 14 controls the VSP module 16 to gradually decrease the pressure level of the emitted sound from the third sound pressure level to the first sound pressure level (similar to time t 10 in FIG. 4 ). Naturally, if the third pressure level is the same as the first pressure level, no such decrease needs to be performed, and the processing can continue as discussed above with regard to FIG. 5 . [0051] As discussed above with regard to FIGS. 2A and 2B , the controller 14 determines in step 150 whether the motive state is a vehicle forward movement position (e.g., a drive transmission position or any forward motive gear position) or a vehicle reverse movement position (i.e., a reverse transmission position). If the controller 14 determines that the motive state is a vehicle reverse movement position, the processing continues to step 280 where the controller 14 controls the VSP module 16 to emit a reverse movement sound as shown in FIG. 6 . FIG. 6 illustrates an exemplary graph of operations that the controller 14 can perform when the motive state is a vehicle reverse movement position. The graph shown in FIG. 6 from times t 0 through t 3 generally corresponds to the graph shown in FIG. 3 from times t 0 through t 3 . However, in FIG. 6 , time t 3 indicates the time that the controller 14 determines that the motive state is a vehicle reverse movement position. [0052] Accordingly, in step 280 , the controller 14 controls the VSP module 16 to emanate the sound, including pulsing the sound when the vehicle movement state indicates intent to move the vehicle 12 and the transmission state is a vehicle reverse movement position. The controller 14 can control the VSP module 16 to pulse the sound between zero and a second level, or between a level greater than zero and the second level. The second level can be greater than or equal to the first level, for example, or the fourth level shown in FIG. 6 which is discussed below. Also, while the transmission is in the vehicle reverse movement position, the controller 14 can continue to detect signals from accelerator position sensor 20 , the speed sensor 22 , the brake state detector 24 and the transmission state detector 26 . Thus, when the controller 14 determines in step 290 that the vehicle 12 is still stationary, the controller 14 can control the VSP module 16 to continue to pulse the sound in step 280 . [0053] However, when the brake is in the brake released state and the controller 14 determines, for example, from the speed sensor 22 or the accelerator position sensor 20 that the accelerator is in the accelerator depressed state and the vehicle 12 is thus moving (time t 4 in FIG. 6 ), the processing can continue to step 200 and repeat as discussed above. In other words, although not shown explicitly in FIG. 6 , the controller 14 can change the peak sound pressure (volume) of the emitted sound based on the acceleration (or speed) of the vehicle 12 in the reverse direction in a manner similar to that described above with regard to the forward movement of the vehicle 12 . The controller 14 can still control the VSP module 16 to continue to pulse the sound even during this increase and decrease in peak sound pressure based on acceleration and deceleration of the vehicle 12 . Naturally, the controller 14 can change the rate of pulsing (e.g., increase or decrease the rate of pulsing or cadence rate) when the vehicle 12 is being accelerated or decelerated in the reverse direction. Of course, the controller 14 can alternatively control the VSP module 16 to continue to pulse the sound between the same levels (volumes) and at the same pitch and cadence regardless of the acceleration and deceleration of the vehicle 12 as shown in FIG. 6 . [0054] While repeating the operations shown in FIGS. 2A and 2B in a manner similar to that for the forward movement of the vehicle 12 as discussed above, the controller 14 can determine that the brake is in the brake depressed state (time t 5 in FIG. 6 ) and the vehicle 12 is stopped (time t 6 in FIG. 6 ). The controller 14 can thus determine whether the transmission position has changed in steps 140 and 150 as discussed above. If the transmission position has not changed from the reverse vehicle position, the controller 14 will control the VSP module 16 to continue to pulse the sound as discussed above. However, if the controller 14 determines in step 150 that the transmission position has changed to, for example, a vehicle forward movement position, the processing will proceed to step 160 and repeat as discussed above. As indicated, times t 6 , t 7 , t 8 and t 9 in FIG. 6 generally correspond to times t 3 , t 4 , t 5 and t 6 , respectively, in FIG. 3 . Thus, the operations performed at times t 6 , t 7 , t 8 and t 9 in FIG. 6 generally correspond to the operations performed at times t 3 , t 4 , t 5 and t 6 , respectively, in FIG. 3 as discussed above. Also, the third, fourth and fifth sound levels shown in FIG. 6 generally correspond with the second, third and fourth sound levels, respectively, shown in FIG. 3 . Naturally, as discussed above with regard to FIGS. 3-5 , the controller 14 can control the VSP module 16 to maintain the sound pressure level at the fourth sound pressure level as shown in broken line in FIG. 6 , or at any other suitable sound pressure level, during vehicle acceleration as long as the speed of the vehicle 12 is at or below a predetermined speed. General Interpretation Of Terms [0055] In understanding the scope of the present invention, the term “comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps. The foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives. Also, the terms “part,” “section,” “portion,” “member” or “element” when used in the singular can have the dual meaning of a single part or a plurality of parts. Also, the term “detect” as used herein to describe an operation or function carried out by a component, a section, a device or the like includes a component, a section, a device or the like that does not require physical detection, but rather includes determining, measuring, modeling, predicting or computing or the like to carry out the operation or function. The term “configured” as used herein to describe a component, section or part of a device includes hardware and/or software that is constructed and/or programmed to carry out the desired function. The terms of degree such as “substantially”, “about” and “approximately” as used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. [0056] While only selected embodiments have been chosen to illustrate the present invention, it will be apparent to those skilled in the art from this disclosure that various changes and modifications can be made herein without departing from the scope of the invention as defined in the appended claims. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components that are shown directly connected or contacting each other can have intermediate structures disposed between them. The functions of one element can be performed by two, and vice versa. The structures and functions of one embodiment can be adopted in another embodiment. It is not necessary for all advantages to be present in a particular embodiment at the same time. Every feature which is unique from the prior art, alone or in combination with other features, also should be considered a separate description of further inventions by the applicant, including the structural and/or functional concepts embodied by such feature(s). Thus, the foregoing descriptions of the embodiments according to the present invention are provided for illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
A method of emanating a sound from a vehicle comprising detecting a speed of the vehicle, and emanating a speed sound, including emanating a sound profile and changing at least one of a sound pressure level and a pitch of the sound profile in relation to the speed of the vehicle changing. The method further comprises ceasing emanation of the speed sound upon the speed of the vehicle increasing from below a first threshold to above the first threshold, and resuming emanation of the speed sound upon the speed of the vehicle decreasing from above a second threshold to below the second threshold, the second threshold being less than the first threshold.
1
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to U.S. provisional application Serial No. 60/304,599, filed Jul. 10, 2001, which is hereby incorporated by reference in its entirety to the extent not inconsistent with the disclosure herewith. BACKGROUND OF THE INVENTION [0002] This invention is in the field of reducing or eliminating acid rock drainage from sulfidic iron containing rocks and acidic mine waste tailings. Acid rock drainage (formation of sulfuric acid and related acids from natural air/water oxidation processes on various materials) is a common phenomenon from mining and leaching of various metallic and non-metallic minerals such as iron-containing sulfidic materials. These sulfidic materials include tailings, overburden, discarded waste rock and unmined exposed rock. Acid rock drainage causes severe pollution problems throughout the world. [0003] There have been various attempts to render these sulfidic materials non-reactive which include partially converting pyrite and pyrrhotite into an oxide structure so that each iron sulfide particle is coated with an iron oxide film, microencapsulation of pyrite by artificial inducement of iron phosphate coatings, the coating of exposed surfaces with various polymeric materials, and the formation of manganese dioxide coatings on pyrite surfaces. These methods of treating materials have been at best partially effective and economically unattractive. [0004] U.S. Pat. No. 5,587,001 (DeVries, Dec. 24, 1996) describes a method for reducing acid rock drainage from sulfidic iron-containing rock by contacting the rock with an aqueous solution of manganate ion at a pH between 6-13. This treatment reportedly creates a manganese oxide layer on the iron-containing sulfidic rock. The process in the U.S. Pat. No. 5,587,001 requires pH 6-13 at all times during the treatment, preferably a pH greater than 10. U.S. Pat. No. 5,587,001 also requires that permanganata color be maintained during the treatment. This condition often requires high dosage of manganate ions for treating reactive tailings because a considerable amount of manganate ions are dissolved in solution and react with other ions before reaching the sulfide surface. U.S. Pat. No. 5,587,001 also requires that the sulfides contain a significant concentration of iron bearing minerals so that the reaction between iron bearing sulfides and permanganate ions can be sustained. Several dissolved metals undergo precipitation reactions at pH>12. Precipitated metal hydoxycomplexes coat the sulfides, thus preventing the desired electrochemical reaction. [0005] U.S. Pat. No. 6,086,847 (Thompson, Jul. 11, 2000) discloses a process for reportedly preventing acid rock drainage of metal-bearing rocks comprising contacting a sulfidic iron-containing rock with an acid passivating agent which comprises at least one alkaline earth metal to produce a combination; contacting the combination with manganate ions and a base and maintaining the pH of the system between 11 and 13.5. [0006] The waste rock naturally yields very low acidic pH in the range of 1-4. To raise the pH and maintain it at a higher level than is naturally found (such as the pH required by the process disclosed in U.S. Pat. Nos. 5,587,001 and 6,086,847) requires high dosage of neutralization agents (for example, lime/caustic soda). This is not economically and technically viable. Also, at high pH (above about 11.0), gypsum (CaSO 4 ) and MgSO 4 precipitate on the sulfide and complete coating of desired materials cannot be achieved. Improved and cost effective treatments are necessary to treat iron containing sulfidic minerals to prevent or minimize the natural oxidation of these materials to form acids. SUMMARY OF THE INVENTION [0007] A method for passivating sulfidic iron-containing rock and mine wastes is provided. This method is useful to reduce the amount of acid rock drainage from mine waste tailings and other areas where formation of acid products is a problem, among other uses. The process disclosed herein is independent of the concentration of iron sulfide in the materials to be treated and the physical state of materials. Also, the low pH treatment ensures that the sulfide surfaces are exposed and are in direct contact with the layers of coating agents. [0008] The tailings, waste rock and other exposed surfaces at mining operations can react with atmospheric air and surface water over a period of time forming polluting acid drainage. Formation of magnesium oxysulfate coatings on iron-containing sulfides shield them from atmospheric air or surface water containing oxygen to prevent or minimize acid drainage problems. [0009] As used herein, “passivating” means rendering the substance passivated less reactive than it was before passivation. For example, a passivated sulfidic iron-containing ore is an ore that generates no acid or less acid than a non-passivated ore upon being exposed to acid-generating and/or weathering processes. An “effective amount” is an amount that given the desired effect, as taught herein. [0010] In one embodiment, the process of this invention for passivating sulfidic iron-containing rock comprises the steps of: [0011] contacting said rock with a magnesium-containing substance; if necessary, adjusting the pH of the slurry so that magnesium oxysulfate is formed; optionally adding silicates, for example, sodium or calcium silicates; optionally allowing oxidation of the rock to form oxysulfates on a surface of the rock; and optionally adding an iron-containing substance, for example FeCl 3 or Fe 2 (SO 4 ) 3 to form ferrous iron-magnesium sulfates. [0012] The magnesium-containing substance used can be any suitable composition such as one or more members of the group consisting of magnesium oxide, magnesium hydroxide, magnesium chloride, magnesium nitrate and magnesium carbonate. In addition, any suitable form can be used. For example, an aqueous saturated solution may be used, or dry solid may be used. The use of magnesium hydroxide prevents reaching of overdose level of alkali. An overdose level of alkali is the concentration that blocks solution passage and permeability. The use of MgO maintains the pH at near 9 and below. Preferably, the magnesium-containing substance is in the form of an aqueous saturated solution of magnesium oxide or dry magnesium oxide (about 2.2-22.0 lbs MgO/ton of rock which is about 0.1-1% magnesium oxide by weight in the solution) or magnesium hydroxide (preferably 2.5% by weight of solution magnesium hydroxide). [0013] Preferably, the rock and magnesium are reacted in the form of a slurry. The rock can be directly treated in the natural environment or as crushed rock preferably containing about 20%-50% by weight of solids, but any concentration or range of concentrations which allows the desired reaction to occur at a desired rate is included in this description. When magnesium oxide is used, the weight ratio of magnesium oxide: rock: water is preferably maintained at up to 1:100:400-10:100:400. [0014] The pH of the rock slurry is usually between about 1 and 5 as it naturally occurs. It is generally not necessary to adjust the pH of the slurry before treatment. If the pH of the starting system is greater than about 4-5, pH adjustment is needed using any suitable pH adjustment treatment, as described further herein and as is known in the art without undue experimentation. [0015] After the magnesium-containing substance is contacted with the rock for a time sufficient to form magnesium sulfate as determined by means known in the art, the pH is raised by any means known in the art (preferably calcium oxide or sodium hydroxide are added) to causes the formation of magnesium oxysulfate (preferably the pH is raised to 9-11 for the formation of magnesium oxysulfate). At this point, the reactive sulfide in the rock is stabilized. Optional oxidation of the slurry, preferably with air, but any oxidizing agent may be used, results in the formation of different phases of oxysulfates on the surfaces of the sulfides. If desired, an effective amount (for example, 1-5 lb/ton rock) of silicate (for example, sodium silicate or calcium silicate) added at any stage of the process increases the strength of the coating due to formation of magnesium sulfate and magnesium silicate compounds. Any amount of silicate that causes formation of magnesium sulfate or magnesium silicate can be used. If desired, an iron-containing substance such as an iron salt may be added in a suitable concentration to form ferrous iron-magnesium sulfates. The iron salt may be any suitable salt known to one of ordinary skill in the art, including FeCl 3 . The concentration of iron-containing substance added is any concentration sufficient to form the desired amount of ferrous iron-magnesium sulfate. If there is a low concentration of dissolved iron, enough iron must be added to form the complex. This is typically 1-2 lb/ton of ore. [0016] A presently-preferred embodiment of the process is the method of reducing acid rock drainage from sulfidic iron-containing rock comprising the steps of contacting said rock with dry/hydrated magnesium oxide wherein the concentration of magnesium oxide in the mixture is 0.1-1% by weight and the slurry density is about 20% by weight of solids in the mixture, and the pH of the resultant slurry is between 1-5; allowing a reaction between magnesium oxide and the sulfides in said rock to proceed so as to form in slurry dissolved magnesium sulfate; raising the pH of the slurry to form magnesium oxysulfate (preferably by the addition of CaO or sodium hydroxide, and preferably to about 10-10.5); optionally adding silicates of sodium or calcium; optionally performing air oxidation of slurry so as to cause the formation of magnesium oxysulfates coating on the surface of said sulfides. [0017] Another preferred embodiment of the process is a process for reducing acid rock drainage from sulfidic iron-containing rock comprising the steps of: [0018] contacting said rock with an aqueous colloidal suspension of 2.5% magnesium hydroxide; allowing a reaction between magnesium hydroxide and the sulfides in said rock to proceed; raising the pH of the slurry to form magnesium oxysulfate (preferably by the addition of CaO or sodium hydroxide, preferably to about 10-10.5); optionally adding silicates of sodium or calcium; optionally performing air oxidation of slurry; optionally adding FeCl 3 or other iron salts. BRIEF DESCRIPTION OF THE FIGURE [0019] [0019]FIG. 1 shows solution pH of pyrite sample in the hydrogen peroxide test as a function of time after passivation using MgO and silicate. DETAILED DESCRIPTION OF THE INVENTION [0020] The ores that may be treated using the method of the invention include pyrrhotite, bomite, chalcopyrite, arsenopyrite and pyrite. Any ore that contains iron and sulfur in its reduced form (sulfide) may be treated to passivate the sulfur using the disclosed process. The ore may be in any form, for example, slurry, rock pile or exposed rock. [0021] The reaction proceeds for a suitable time required to achieve the desired amount of passivation of the sulfur in the ore. This time naturally depends on the nature of the ore treated, the desired amount of passivation of the sulfur in the rock and other parameters, such as concentration of reactants used. This time is readily determined by routine experimentation well within the skill of one of ordinary skill in the art without undue experimentation, using the teachings herein. [0022] The processes of this invention can be carried out at temperatures above the freezing point of the solutions up to about 60° C. [0023] Applicant does not wish to be bound by any theory presented herein. The theory and examples below are presented to aid in the understanding of the invention and illustrating some of the presently-preferred embodiments of the invention. EXAMPLE 1 [0024] Effect of Magnesium Oxide Dosage on Passivation in the Presence of Permanganate [0025] 5 gms −325 mesh pure pyrite sample was mixed with 20 mg of lime to increase the pH to basic pH (about 10.5). In place of lime, caustic soda or sodium carbonate or other suitable materials that increase the pH to the desired range may be added. Different dosage levels of magnesium oxide were used (0, 2.2 lbs magnesium oxide/ton rock, 4.4 lbs./t, 8.8 lbs./t, 13.2 lbs./t and 22.0 lbs./t). 20 ml. of tap water was added to the mixture of pyrite, lime and magnesium oxide and the slurry pH were measured to be about 1.5. The slurry pH was then raised to 10-10.3 by the addition of 1 N NaOH. At this point, 1.32 lbs./t of permanganate was added. The slurry was left undisturbed for 2 hours. The slurry was filtered and the solids were washed. The washed solids were suspended in 91 ml. of water and to this 9 ml. of 50% hydrogen peroxide was added. The pH of the solution was monitored for 1 day. At the end of 1-day duration, the tests which showed pH of above 7, were considered to be successful tests in-terms of passivation. If the pH drops below 7 much before 24 hours, the test is also considered a fail. The results are presented in Table 1 below. TABLE 1 Peroxide Tests Results with different dosage of MgO. The KMnO 4 dosage was maintained constant in each test (1.32 lbs./T) MgO Dosage Peroxide (lbs./t) Test Result Remarks 0 Failed Vigorous reaction, fails at 60 minutes 2.2 Failed Vigorous reaction, fails at 60 minutes 4.4 Failed Vigorous reaction, fails at 60 minutes 8.8 Failed Slow reaction, fails after 1 day 13.2 Failed Slow reaction, fails after 1 day 22.0 Passed Slow reaction, pH above 7.8 [0026] These results show that at lower dosages of MgO, passivation was not effective due to enormous surface area of pyrite involved. However, when the dosage was increased to 22 lbs./t level, the pyrite was successfully passivated. Considering the fact that in mine tailings sample, the pyrite present is fraction of the total sample, the dosage level of MgO required to passivate an actual sample will be at considerably lesser dosage level than 22 lbs./t. [0027] These results show that in order to passivate the same pyrite sample, MgO dosage level of 22 lbs./t was required. Note that in these experiments, permanganate dosage level of 1.37 lbs./t was present. Since permanganate is beneficial in passivating the pyrite sample (as indicated in U.S. Pat. No. 5,587,001), it was not clear as to what extent MgO was responsible for the passivation. EXAMPLE 2 [0028] Effect of Potassium Permanganate Dosage on Passivation in the Presence of MgO [0029] 5 gms −325 mesh pure pyrite sample was mixed with 10 mg of MgO and 20 mg of lime. This amounts to 4.4 lbs./t of MgO and 8.8 lbs./t of CaO. 20 ml. of tap water was added to the mixture of pyrite, lime and magnesium oxide and the slurry pH were measured to be about 1.5. The slurry pH was then raised to 10-10.3 by the addition of 1 N NaOH. At this point, different dosage of permanganate (0, 1.32 lbs./t, 2.64 lbs./t, 5.28 lbs./t, 10.56 lbs./t, 21.12 lbs./t) was added. The slurry was left undisturbed for 2 hours. The slurry was filtered and the solids were washed. The washed solids were suspended in 91 ml. of water and to this 9 ml. of 50% hydrogen peroxide was added. The pH of the solution was monitored for 1 day. At the end of 1-day duration, the tests which showed pH of above 7, were considered to be successful tests in-terms of passivation. The results are presented below in Table 2. TABLE 2 Peroxide Tests Results with different dosage of KMnO 4 . The MgO dosage was maintained constant in each test (4.4 lbs./T) KMnO 4 Peroxide Dosage (lbs./t) Test Result Remarks 0 Failed Vigorous reaction, fails at 60 minutes 1.32 Failed Vigorous reaction, fails at 60 minutes 2.64 Failed Vigorous reaction, fails at 60 minutes 5.28 Failed Vigorous reaction, fails at 60 minutes 10.56 Failed Vigorous reaction, fails after 1 day 21.12 Passed Slow reaction, pH above 9 [0030] These results show that in order to passivate the same pyrite sample, permanganate dosage level of 21.12 was required. Please note that in these experiments, MgO dosage level of 4.4 lbs./t was present. Since MgO is beneficial in passivating the pyrite sample, it was not clear as to what extent permanganate was responsible for the passivation. EXAMPLE 3 [0031] Effect of Magnesium Oxide Dosage on Passivation in the Absence of Permanganate [0032] 5 gms −325 mesh pure pyrite sample was used. Different dosage levels of magnesium oxide were used (11.0 lbs./t, 15.4 lbs./t, 19.8 lbs./t, and 22.0 lbs./t). 20 ml. of tap water was added to the mixture of pyrite and magnesium oxide. The slurry pH was measured to be about 1.3. The slurry pH was then raised to 10-10.3 by the addition of 1 N NaOH. The slurry was left undisturbed for 2 hours. The slurry was filtered and the solids were washed. The washed solids were suspended in 91 ml. of water and to this 9 ml. of 50% hydrogen peroxide was added. The pH of the solution was monitored for 1 day. At the end of 1-day duration, the tests which showed pH of above 7, were considered to be successful tests in-terms of passivation. The results are presented in Table 3 below. TABLE 3 Peroxide Tests Results with different dosage of MgO in the absence of KMnO 4 . MgO Dosage Peroxide (lbs./t) Test Result Remarks 11.0 Failed Vigorous reaction, fails at 60 minutes 15.4 Failed Vigorous reaction, fails at 60 minutes 19.8 Failed Vigorous reaction, fails at 60 minutes 22.0 Passed Slow reaction, pH above 7.5 [0033] Comparing the results of Table 1 and Table 3, it is clear that the presence of permanganate does not favorably affect the passivation process. To passivate the pyrite sample, 22.0 lbs./t of MgO was needed regardless of the presence of permanganate in the solution. EXAMPLE 4 [0034] Effect of Potassium Permanganate Dosage on Passivation in the Absence of MgO [0035] 5 gms −325 mesh pure pyrite sample was used. 20 ml. of tap water was added to the pyrite and the slurry pH was measured to be about 1.3. The slurry pH was then raised to about 8 by the addition of 1 N NaOH. At this point, different dosage of permanganate (6.6 lbs./t, 11.0 lbs./t, 13.2lbs/t, 15.4lbs./t and 22.0 lbs./t) was added. The final pH was adjusted to be 10-10.3. The slurry was left undisturbed for 2 hours. The slurry was filtered and the solids were washed. The washed solids were suspended in 91 ml. of water and to this 9 ml. of 50% hydrogen peroxide was added. The pH of the solution was monitored for 1 day. At the end of 1-day duration, the tests which showed pH of above 7, were considered to be successful tests in-terms of passivation. The results are presented below in Table 4. [0036] Comparing the results of Table 2 and Table 4, it is clear that permanganate dosage level about 15.4 lbs./t is needed in the absence of MgO to passivate the pyrite. TABLE 4 Peroxide Tests Results with different dosage of KMnO 4 in the absence of MgO KMnO 4 Peroxide Dosage (lbs./t) Test Result Remarks 6.6 Failed Vigorous reaction, fails at 60 minutes 11.0 Failed Vigorous reaction, fails at 60 minutes 13.2 Failed Vigorous reaction, fails at 60 minutes 15.4 Passed Slow reaction, pH above 7 22.0 Passed Slow reaction, pH above 7 [0037] The results listed in Table 1-4 show that the passivation is favorably affected by increasing the dosage level of permanganate and MgO. On a tonnage basis, even though little higher dosage of MgO is required than permanganate, however, considering the enormous price difference between permanganate and MgO (Permanganate $1.50/lb, MgO 50 cents/lb), it is economical to use MgO in place of permanganate. EXAMPLE 5 [0038] Effect of Lime Dosage on Passivation in the Absence of MgO [0039] 5 gms −325 mesh pure pyrite sample was mixed with 100 mg of lime (44.0 lbs./t). 20 ml. of tap water was added to the mixture of pyrite and lime and the slurry pH were measured to be about 4.5. The slurry pH was then raised to 10-10.3 by the addition of 1 N NaOH. At this point, 1.32 lbs./t of permanganate was added. The slurry was left undisturbed for 2 hours. The slurry was filtered and the solids were washed. The washed solids were suspended in 91 ml. of water and to this 9 ml. of 50% hydrogen peroxide was added. The pH of the solution was monitored for 1 day. At the end of 1-day duration, the tests which showed pH of above 7, were considered to be successful tests in-terms of passivation. The results are presented in Table 5 below. TABLE 5 Peroxide Tests Results with High dosage of CaO in the absence of MgO The KMnO 4 dosage was maintained (1.32 lbs./T). CaO Dosage Peroxide (lbs./t) Test Result Remarks 44.0 Failed Vigorous reaction, fails at 60 minutes [0040] As expected even at very high dosage of CaO, the passivation did not occur. EXAMPLE 6 [0041] Effect of Addition of Magnesium Oxide at Higher pH (5.0) on Passivation in the Absence of Permanganate [0042] 5 gms −325 mesh pure pyrite sample was mixed with 20 mg of CaO. 20 ml. of tap water was added to the mixture of pyrite and lime. The slurry pH was then raised to 5 by the addition of 1 N NaOH. At pH 5.0, 22 lbs./t of MgO was added. The pH was then raised to 10-10.3. The slurry was left undisturbed for 2 hours. The slurry was filtered and the solids were washed. The washed solids were suspended in 91 ml. of water and to this 9 ml. of 50% hydrogen peroxide was added. The pH of the solution was monitored for 1 day. At the end of 1 day duration, the tests which show pH greater than 7 were considered successful in terms of passivation. The results are presented in Table 6 below. TABLE 6 Peroxide Tests Results with MgO added at pH 5.0 in the absence of KMnO 4 . MgO Dosage Peroxide (lbs./t) Test Result Remarks 22.0 Passed Slow reaction, pH above 7.5 [0043] Comparing the results of Table 3 and Table 6 it is clear that the addition of MgO whether added at pH 1.7 or at pH 5.7 does not make any difference. EXAMPLE 7 [0044] Effect of the Addition of Hydrated Magnesium Oxide on Passivation [0045] 5 gms −325 mesh pure pyrite sample was mixed with 20 mg of CaO. 20 ml. of tap water was added to the 50 mg of MgO, which resulted in the pH of 10.3. This hydrated MgO slurry was added to the mixture of pyrite and lime. The slurry pH was then raised to 10-10.3 by the addition of 1 N NaOH and 1.32 lbs./t KMnO 4 was added. The slurry was left undisturbed for 2 hours. The slurry was filtered and the solids were washed. The washed solids were suspended in 91 ml. of water and to this 9 ml. of 50% hydrogen peroxide was added. The pH of the solution was monitored for 1 day. At the end of 1 day duration, the tests which showed pH of above 7 were considered to be successful tests in-terms of passivation. The results are presented in Table 7 below. TABLE 7 Peroxide Tests Results with the MgO addition in Hydrated Form MgO Dosage Peroxide (lbs./t) Test Result Remarks 22.0 Passed Slow reaction, pH above 7.5 [0046] Comparing the results of Table 3, Table 6 and Table 7 it is clear that the pH and the form of MgO does not affect the passivation process. EXAMPLE 8 [0047] MgO as Limiting Factor in the Passivation Process [0048] 5 gms −325 mesh pure pyrite sample was mixed with 50 mg (22.0 lbs./t) of MgO and 20 mg of CaO. 20 ml. of tap water was added to the mixture of pyrite, lime and magnesium oxide and the slurry pH were measured to be about 1.65. The slurry was subjected to different treatments, such as pH adjustment to 10.0 and 12.0 followed by with and without aeration, KMnO 4 addition at pH 10.0 and 12.0 followed by with and without aeration, KMnO 4 addition at low pH followed by with and without aeration at pH 10.0. For the tests where there was no aeration, the slurry was left undisturbed for 2 hours. The slurry was then filtered and the solids were washed. The washed solids were suspended in 91 ml. of water and to this 9 ml. of 50% hydrogen peroxide was added. The pH of the solution was monitored for 2 days. The tests which showed pH of above 7, were considered to be successful tests in-terms of passivation. The test conditions and results are presented in Table 8 below. TABLE 8 Peroxide Tests Results with different conditions in the presence of 22.0 lbs./t of MgO Peroxide Conditions Test Result pH measured after 2 days Adjusted to pH 10.0 Passed Final pH 7.62 Adjusted to pH 12.0 Passed Final pH 8.08 Adjusted to pH 10, Passed Final pH 7.65 2 hours of Aeration Adjusted to pH 10 + added Passed Final pH 7.82 1.37 lbs./t of permanganate Adjusted to pH 10 + added Passed Final pH 7.65 1.37 lbs./t of permanganate, 2 hours of aeration Adjusted to pH 12 + 1.37 Passed Final pH 8.05 lbs./t of permanganate Added 1.37 lbs./t of Passed Final pH 7.59 permanganate at pH 1.7, Increase pH to 10 Added 1.37 lbs./t of Passed Final pH 7.58 permanganate at pH 1.7 Increase pH to 10, 2 hours of aeration Added 1.37 lbs./t of Passed Final pH 7.85 permanganate at pH 5.7, Increase pH to 10, 2 hours of aeration [0049] The results listed in Table 8 clearly show that the addition of MgO is a limiting factor in the passivation process. As long as the 22-lbs./t-dosage level of MgO was met in the experiment, the passivation is successfully achieved in all the tests. However, the pH monitoring data shows that the aeration is beneficial during the passivation treatment and brings down the dosage level of MgO required to achieve the passivation. EXAMPLE 9 [0050] Effect of Magnesium Oxide Dosage on Passivation for Hecla Tailing Sample [0051] 5 gms of as-received dry Hecla tailings sample was mixed with 20 mg of CaO and different dosage levels of magnesium oxide (0, 2.2 lbs./t, 4.4 lbs./t, 8.8 lbs./t). 20 ml. of tap water was added to the mixture of pyrite, lime and magnesium oxide. Hecla is a mine in Idaho. The slurry pH was measured to be about 12.02, 12.28, 12.3 and 12.4 respectively. The slurry was left undisturbed for 2 hours. The slurry was filtered and the solids were washed. The washed solids were suspended in 91 ml. of water and to this 9 ml. of 50% hydrogen peroxide was added. The pH of the solution was monitored for 1 day. At the end of 1-day duration, the tests which showed pH of above 7, were considered to be successful tests in-terms of passivation. The results are presented in Table 9 below. TABLE 9 Peroxide Tests Results for the Hecla Tailings Sample with Different Dosage of MgO. MgO Dosage Peroxide (lbs./T) Test Result Final pH after 1 day 0 Failed 4.3 2.2 Passed 7.28 4.4 Passed 8.03 8.8 Passed 8.20 [0052] The data in Table 9 shows that much lower dosage of MgO (<2.2 lbs./t) was required as opposed to 22 lbs./t in the case of pyrite. EXAMPLE 10 [0053] Effect of Magnesium Oxide Dosage on Passivation for Nevada Mine Tailings Sample [0054] 5 gms of as-received dry mine tailings sample from a mine in Nevada was mixed with 20 mg of CaO and different dosage levels of magnesium oxide (0, 2.2 lbs./t, 4.4 lbs./t, 8.8 lbs./t, 13.20 lbs./t, 17.60 lbs./t). 20 ml. of tap water was added to the mixture of pyrite, lime and magnesium oxide. The slurry pH was adjusted to 10.0 with 1 N NaOH. The slurry was left undisturbed for 2 hours. The slurry was filtered and the solids were washed. The washed solids were suspended in 91 ml. of water and to this 9 ml. of 50% hydrogen peroxide was added. The pH of the solution was monitored for 1 day. At the end of 1-day duration, the tests which showed pH of above 7, were considered to be successful tests in-terms of passivation. The results are presented in Table 10 below. TABLE 10 Peroxide Tests Results for Mine Tailings Sample with Different Dosage of MgO. MgO Dosage Peroxide (lbs./T) Test Result Remarks 0 Failed pH 2.54 after 3 hours 2.2 Failed pH 2.57 after 3 hours 4.4 Failed pH 2.59 after 3 hours 8.8 Failed pH 3.58 after 3 hours 13.20 Passed Final pH after 1 day 7.22 17.60 Passed Final pH after 1 day 7.42 [0055] The data in Table 10 shows that much lower dosage of MgO (<13.2 lbs./t) was required as compared to 22 lbs./t in the case of pyrite. EXAMPLE 11 [0056] Effect of Magnesium Oxide Dosage on Passivation for Ruby Gulch Tailings Sample [0057] 5 gms of as-received dry Ruby Gulch tailings sample was mixed with 20 mg of CaO and different dosage levels of magnesium oxide (0, 2.2 lbs./t, 4.4 lbs./t, 8.8 lbs./t, 13.20 lbs./t). 20 ml. of tap water was added to the mixture of pyrite, lime and magnesium oxide. Ruby Gulch is a mining site in South Dakota. The slurry pH was adjusted to 10.0 with 1 N NaOH. The slurry was left undisturbed for 2 hours. The slurry was filtered and the solids were washed. The washed solids were suspended in 91 ml. of water and to this 9 ml. of 50% hydrogen peroxide was added. The pH of the solution was monitored for 1 day. At the end of 1-day duration, the tests which showed pH of above 7, were considered to be successful tests in-terms of passivation. The results are presented in Table 11 below. TABLE 11 Peroxide Tests Results for the Ruby Gulch Tailings Sample with Different Dosage of MgO. MgO Dosage (lbs./T) Peroxide Test Result Remarks 0 Failed pH 3.16 after 3 hours 2.2 Failed pH 3.52 after 3 hours 4.4 Failed pH 6.34 after 1 day 8.8 Passed Final pH after 1 day 7.17 13.20 Passed Final pH after 1 day 7.82 [0058] The data in Table 11 shows that much lower dosage of MgO (<8.8 lbs./t) was required as opposed to 22 lbs./t in the case of pyrite. [0059] A large column test was performed using magnesium oxide. The pH during passivation was maintained at 10 using MgO only. MgO was added as a passivating agent. After passivation, a sample representing 150 grams of solid was transferred to the humidity cell experiment. The humidity cell experiment was operated on seven-day cycles. In the first three days dry air was passed into the sample, followed by three-day moisturized air treatment. On the seventh day the sample was leached and the leachate was analyzed for pH, alkalinity, acidity, sulfate and other elements. Long-term testing with Ruby Gulch tailings affirmed the effectiveness of the process, as shown in Table 12. [0060] In the table below, each cycle is for the same sample and is reported as the function number of cycles. TABLE 12 Analysis of leachates obtained from humidity cell experiments (Column test, Ruby Gulch - Waste Dump Sample, High Sulfide) Sample weight: 4000 g Dosage: 7.7 lbs./t Magnesium Oxide Sample CYCLE-1 CYCLE-2 CYCLE-3 CYCLE-4 CYCLE-5 CYCLE-6 Constituents (mg/l) (mg/l) (mg/l) (mg/l) (mg/l) (mg/l) PH 7.63 8.05 7.61 8.31 8.32 8.09 Conductivity 920 890 460 370 225 220 (μυ/cm) Acidity as 0 <15 <15 <15 <15 <15 CaCO 3 Alkalinity as 44 30 40 25 45 30 CaCO 3 Calcium 19.8 18.9 16.9 13.8 11.1 11.4 Iron 0.028 0.051 0.030 <0.020 <0.020 0.020 Magnesium 127 104 42.7 32.6 14.2 13.6 Manganese 0.036 <0.010 <0.010 <0.010 <0.010 <0.010 Sulfate 492 139 95.6 28.4 26.3 27.8 TDS 700 560 235 238 175 <50 Antimony <0.003 <0.006 0.006 <0.006 <0.006 <0.006 Barium <0.050 0.061 0.064 0.080 0.075 0.075 Beryllium <0.002 <0.002 <0.002 <0.002 <0.002 <0.002 Cadmium <0.002 <0.003 <0.003 <0.003 <0.003 <0.003 Chromium <0.010 <0.010 <0.010 <0.010 <0.010 <0.010 Cobalt <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 Copper <0.010 <0.010 <0.010 <0.010 <0.010 <0.010 Lead <0.007 <0.007 <0.007 <0.007 <0.007 <0.007 Mercury <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 Molybdenum <0.050 <0.050 <0.050 <0.050 <0.050 <0.050 Nickel <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 Selenium <0.007 <0.007 <0.007 <0.007 <0.007 <0.007 Silver <0.035 <0.035 <0.035 <0.035 <0.035 <0.035 Thallium <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 Vanadium <0.100 <0.100 <0.100 <0.100 <0.100 <0.100 Zinc <0.050 <0.050 <0.050 <0.050 <0.050 <0.050 EXAMPLE 12 [0061] Combined Effect of Sodium Silicate with MgO [0062] In another series of experiments the combined effect MgO with silicate were tested. The pH of the pyrite sample was increased to 10.5 with CaO and a small amount of sodium silicate was added prior to MgO addition. After reaction, the sample was filtered and H 2 O 2 test was conducted as described above. The results are shown in Table 13. TABLE 13 Peroxide Tests Results for the Pyrite Sample with Different Dosage of MgO and Sodium Silicate. MgO Dosage Sodium Silicate Peroxide (lbs./T) Dosage (lbs./T) Test Result Remarks 13.2 0 Failed pH 3.70 after 3 hours 17.6 0 Failed pH 4.30 after 3 hours 22.0 0 Passed Final pH after 1 day 7.80 26.4 0 Passed Final pH after 1 day 8.30 17.6 4.4 Passed Final pH after 1 day 7.81 22.0 4.4 Passed Final pH after 1 day 8.30 [0063] As can be seen in Table 13, with addition of only 17.6 lbs./t MgO, pyrite was not passivated. However, addition of 4.4 lbs./t sodium silicate in the presence of 17.6 lb/ton MgO increased the stability and the pH remained about 7.81. It is evident that sodium silicate improves the passivation. [0064] The effect of silicate addition is also demonstrated in FIG. 1. As can be seen, passivated pyrite samples with MgO and silicate in the presence of lime showed improved resistance to peroxide oxidation as compared to samples with no silicate. [0065] Combined Effect of Calcium Silicate with MgO [0066] In another series of experiments the combined effect of MgO with calcium silicate was tested. The pH of the pyrite sample was increased to 10.5 with CaO and a small amount of calcium silicate was added prior to MgO addition. After reaction, the sample was filtered and an H 2 O 2 test was conducted as above. The results are given in Table 14. TABLE 14 Peroxide Test Results for the Pyrite Sample with Different Dosage of MgO and Calcium Silicate. (MgO Dosage, Calcium Silicate Peroxide Test lb/T) (lb/T) Result Remarks 13.2 0 Failed pH 3.7 after 3 hrs 17.6 0 Failed pH 3.78 after 24 hrs 17.6 4.4 Passed pH 7.6 after 24 hours [0067] As can be seen from Table 14, 14.4 lb/ton addition of calcium silicate increased the passivation of pyrite. This shows that calcium silicate can be used in conjunction with CaO to passivate pyrite at pH 10.5. REFERENCES [0068] 1. Caruccio, F. T., Geidel, G., Pelletier, M., “Occurrence and predication of acid drainage”. J. of the Energy Division, ASCE, 107, No. 1, pp.167, 1981. [0069] 2. De Vries, Nadine H. C. Process for Treating Iron-Containing Sulfide Rocks and Ores, U.S. Pat. No. 5,587,001, 1996. [0070] 3. Doyle, F. M. and Mirza, A. H., “Understanding the mechanisms and kinetics of pyrite wastes”. Proceedings of the Western Regional Symposium on Mining and Mineral Processing, Doyle, F. M. (eds.), Society of Mining Engineering. 1990. [0071] 4. Evangelou, V. P., “Pyrite Chemistry: The Key for Abatement of Acid Mine Drainage”. Acidic Mining Lakes: Acid mine Drainage, Limnology and Reclamation Springer-Verlag, 1998. [0072] 5. Huang, X. and Evangelou, V. P., Abatement of acid mine drainage by encapsulation of acid producing geological materials, US Bureau of Mines, Contract No. J0309013, 1992. [0073] 6. Kleinmann, R. L. P., “Acid mine drainage: US Bureau of Mines researches and develops control methods for both coal and metal mines”. Enviro. Mining J., July, pp161-164, 1989. [0074] 7. Marshall, G. P., J. S. Thompson, and R. E. Jenkins, “New technology for the prevention of acid rock drainage”. Proceedings of the Randol Gold and Silver Forum, pp. 203, 1998. [0075] 8. Sobek, A. A., Schuller, W. A., Freeman, J. R., and Smith, R. M., Field and laboratory methods applicable to overburden mine soils. EPA 600/2-78-054, pp203, 1978. [0076] In the disclosed process, as is generally true for other processes, the fewer chemicals used, the more cost effective the process. If desired, other chemicals can be used in the disclosed process, including barium hydroxide and calcium carbonate for pH control, but it is desired that as few chemicals as possible be used to lower the cost of the process. [0077] All numerical ranges given herein include all useful intermediate ranges and values thereof. Useful ranges and values may be determined using the teachings herein and those known in the art without undue experimentation. Useful chemical equivalents may be used for those chemicals specifically exemplified in this disclosure, as known by one of ordinary skill in the art without undue experimentation. [0078] All references cited herein are hereby incorporated by reference to the extent not inconsistent with the disclosure herein. Although the description herein contains many specificities, these are not to be construed as limiting the scope of the invention, but as merely providing illustrations of some of the presently-preferred embodiments of the invention. For example, the magnesium may be in the form of magnesium oxide, or other forms, as known in the art. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
A method is provided for passivating sulfidic iron-containing rock comprising contacting sulfidic iron-containing rock with one or more members of the group consisting of magnesium oxide, magnesium hydroxide, magnesium chloride, magnesium nitrate and magnesium carbonate, thereby reducing the acid generation potential of rock.
8
BACKGROUND OF THE INVENTION This invention relates to a novel and improved high intensity oscillating jet adaptable for cutting hard rock materials such as granite and the like in a rapid and dependable manner. Various systems have been devised for cutting hard rock materials employing a high intensity jet which will deliver liquid at a sufficiently high pressure and concentration against the surface to form a well defined slit. Typical of this is the method and apparatus set forth in my copending application for patent entitled METHOD & APPARATUS FOR CHANNEL CUTTING OF HARD MATERIALS USING HIGH VELOCITY FLUID JETS, Ser. No. 610, 577, filed 5 Sept. 1975. In that system, a nozzle assembly includes a series of nozzles arranged to form a divergent jet pattern with suspension means for the nozzle assembly which will permit its reciprocation in a direction toward and away from the line to be cut. This system has been found to be particularly effective in forming straight-walled channels or slits for a substantial distance into the material without spalling or substantial jet impedance. Other typical approaches taken to cutting of hard rock materials employing high intensity jets are disclosed in the U.S. Pat. No. 3,883,075, to Edney Noren U.S. Pat. No. 3,960,407 and Sweetman U.S. Pat. No. 2,587,243. It is desirable to provide a jet cutting system which will afford the deepest possible penetration in forming a well defined slit through the material while permitting the cutting operation to proceed at a relatively high rate of speed. Additionally, it is important that the jets be angled into the groove or slot in such a way as to erode a clear and open bottom for the escape of water and eroded material so as not to impede the direct flow of water against the bottom of the grooves. Moreover, in cutting relatively deep channels, it is desirable to so form the channel as to maintain relatively straight walls and to prevent the channel from narrowing while at the same time concentrating the jet stream across a uniform width. SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide for a novel and improved method and apparatus for cutting relatively hard rock materials such as granite and the like. It is another object of the present invention to provide a method and means for oscillating a jet stream for impingement at a high intensity along a line or slot to be cut in the material and in such a way as to achieve relatively deep penetration while maintaining a uniform width of the slot or groove throughout. It is a further object of the present invention to provide for a high intensity jet cutting system in which means are provided for oscillating the jet at relatively high frequencies in a duration transversely of the path of travel of the jet in forming a line or slot in a hard rock material to be cut. An additional object of the present invention is to provide for a novel and improved series of high intensity water jets and means for oscillating same which will assure uniform penetration and cutting of rock materials in rapid and efficient manner, and further wherein the jets are capable of traversing either vertical or horizontal lines of cutting in forming well defined channels. In accordance with the present invention a system and method has been devised for cutting hard rock materials utilizing one or more jets. For instance, laboratory testing indicates that a single jet of high pressure fluid on the order of 45,000 lbs. per square inch is capable of cutting a slot in granite on the order of 3/16th of an inch deep by one inch long over a time interval of one second. The same jet is capable of cutting a slot 1/4th of an inch deep by one inch long but with a greatly increased width of slot if the jet is oscillated sideways or transversely of its forward direction of movement along the line to be cut. Accordingly, oscillation at predetermined frequencies is capable of achieving deeper penetration and a wider, but accurately defined, slot or groove when the jet or series of jets is oscillated. Cutting progresses at a much faster rate since the jet is not impeded by cavitation or eroded material within the confines of the slot. Thus for instance the channel formed may be substantially wider and deeper when oscillation is employed even with a single jet since the jet is continually angling and cutting a wider groove. Again however the process has been found to be effective in eroding a clear and open channel for the escape of water and eroded material with a minimum of impedance of the high intensity jet stream. In cutting deep channels in granite or other hard rock materials, it is necessary to have the channel wide enough for entrance of the nozzle producing the jet and allow for its movement through channel. The desired channel width may be obtained by selecting one or more nozzles and preferably in a somewhat divergent pattern so that when oscillated, an accurately defined relatively straight wall with bottom corners is formed. Another desirable feature of the present invention is to utilize somewhat higher intensity or stronger outside jets than the inner jets to achieve optimum penetration and cutting in the bottom corners of the channel. This assures a straight wall and prevents the channel from narrowing as cutting progresses through the channel. The speed of traversal and oscillation may vary with the hardness and composition of the material being cut. Most desirably variable speed motors can control both functions. For instance, a medium hard granite may be cut with a traverse speed on the order of two inches per second and an oscillation rate of 750 cycles per minute, the channel cutting rate being approximately 30 square feet per hour. The cutting rate on limestone or other softer materials could allow for even greater rates of traversal as well as oscillation. One embodiment of the present invention employs a nozzle suspension system including a revolving cam which imparts transverse oscillatory motion to a series of nozzles as the nozzles are advanced along the line to be cut. In another form of the present invention, the nozzle assembly is suspended by a lance or elongated support which is adapted to advance back and forth in a vertical direction perpendicular to the surface of the material, and oscillatory motion in a direction transversely of the path of travel is imparted by a separate liquid delivery system which imparts alternate pulses to the lance causing an oscillatory motion in a direction transversely of the path of travel to be established. In the modified form, most desirably the lance is supported by a shell or other guide member which assures straight entry and exit of the lance in the channels with the jets cutting on the entry and exit trips of the lance as it is caused to reciprocate up and down. Thus the procedure for quarry channeling is to erode the granite on the entry trip, followed by forward advancement of the guide for a limited distance of 1/4th inch and thereafter the traveling jets erode another section of granite on the exit trip. The procedure is repeated as the car moves forward for the re-entry and exit until a relatively deep channel is eroded to the desired depth and length. Horizontal channeling may be achieved by mounting the lance and guide horizontally on the car or other advancing unit. BRIEF DESCRIPTION OF THE DRAWINGS The foregoing and other objects, features and advantages of the present invention will be more readily understood in conjunction with the following description of an exemplary preferred embodiment. FIG. 1 is a somewhat schematic side view of a preferred form of oscillating fluid jet system in accordance with the present invention. FIG. 2 is a somewhat schematic end view of the lower portion of the suspension means and nozzle assembly as shown in FIG. 1 and illustrating the cutting pattern of the jets. FIG. 3 is an enlarged, fragmentary view showing in more detail the lower end of a modified form of nozzle assembly adaptable for use with the suspension means of FIGS. 1 and 2. FIG. 4 is a front view of the nozzle assembly as shown in FIG. 3. FIG. 5 is a cross-sectional view taken about lines 5--5 of FIG. 3. FIG. 6 is a cross-sectional view taken about lines 6--6 of FIG. 3. FIG. 7 is a sectional view illustrating the nozzle arrangement shown in FIG. 3. FIG. 7A is an end view of the nozzle assembly showing the arrangement of the nozzles in the nozzle block. FIG. 8 is a somewhat schematic side view of another modified form of oscillating fluid jet cutting system in accordance with the present invention; and FIGS. 8A and 8B are somewhat fragmentary front views of the lower suspension systems and nozzle assembly of the modified form of FIG. 8 and illustrating the path of oscillation of the nozzle assembly. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring in detail to the drawings, a preferred form of oscillating fluid jet cutting apparatus 10 is illustrated in FIGS. 1 and 2, the apparatus being broadly characterized by its ability to oscillate a nozzle assembly 12 as it is advanced simultaneously in a generally vertical or up and down direction, the oscillation and advancement of the nozzle assembly being further coordinated with horizontal advancement or travel of the upper frame assembly 13 along a guide track represented at 14. In the preferred form, the nozzle assembly 12 is comprised of a nozzle block 15 containing a manifold 16 communicating with a supply tube 17 which supplies water under pressure to a series of nozzles or jets 18 which incline downwardly from the manifold 16 and exit through an inclined surface 19 of the nozzle block or holder 15. The nozzle block is rectangular in cross-section with the inclined surface 19 forming a relieved portion along one vertical side of the block, and a recessed portion 11 is formed directly above the inclined surface to facilitate mounting of the lower end of the supply tube 17 in the nozzle block by a union 17' which is threadedly secured to the tube in the recessed portion directly above its connection into the manifold. Although forming no part of the present invention as such, the nozzles or jets 18 may be of the type disclosed in more detail in my hereinbefore referred to copending application for patent Ser. No. 610,577 in which a series of three sapphire nozzles are provided with generally conical bores leading into orifices whereby to concentrate and to discharge the fluid through the orifices in the form of extremely high velocity concentrated streams. The nozzle assembly 12 is suspended by a main sleeve guide 20 which is elongated and of generally rectangular cross-section through which are extended outer, elongated cylindrical supports 21 and 22 and an intermediate cam drive shaft 23 in parallel to one another. The outer support 21 takes the form of an elongated tube or pipe which extends from connection to the lower supply tube 17 by the union 17' in the nozzle assembly upwardly through and connected to the sleeve guide 20 for connection into a high pressure water source, not shown, but which is connected to flexible hose 24 and an elbow-shaped fitting 25 into the tubular support 21. The support 22 preferably takes the form of a solid elongated rod of limited flexibility which is rigidly affixed at its lower end to the nozzle block 15 and extends upwardly to terminate in an upper end above the sleeve guide 20 so as to serve along with the tube 21 as the main means of suspension of the nozzle assembly from the sleeve guide. The cam drive employed in the preferred form of FIGS. 1 and 2 is hereinafter described in more detail with reference to FIGS. 3 and 4 but broadly takes the form of a drive shaft 23 which is journaled for rotation within the sleeve guide 20 and is driven by a variable speed drive motor M coupled to the upper end of the drive shaft 23. In turn the lower end of the drive shaft terminates in a cam 26 which rides in a channel formed in the upper surface of the nozzle block 15 and imparts side-by-side or transverse oscillation to the block; or in other words when viewed from the front as in FIG. 2 will cause the nozzle assembly to be oscillated in a lateral direction in the manner illustrated so as to cause the fluid jets to describe a zig-zag cutting pattern as generally designated at P in FIG. 2. The sleeve guide 20 is slidable through a main horizontal frame or chassis 32, the latter provided with track engaging wheels 33 for advancement of the entire assembly along the guide track 14. A main vertical support is defined by a standard 35 in the form of a vertical I-beam adapted for mounting of upper and lower spaced horizontal frame members 36 and 37 which carry roller pairs 38 and 39, respectively, for slidable movement along horizontally spaced, vertical tracks 40 which are mounted on the vertical support 35. Rolling movement of the roller pairs 38 and 39 is controlled by a suitable chain or belt drive and here defined by a chain 42 trained over upper and lower sprockets 43 and 44 with one end 45 of the chain affixed to the lower frame or bar 37 and the other end 46 affixed to the upper frame 36. Vertical motion is imparted to the chain drive by a reversible drive motor M' which has its drive shaft drivingly connected to a pulley 48 over which is trained a power transmission belt 49 leading into a driven pulley 50, the latter keyed for rotation on the axle for sprocket 44 so that continuous rotation of the pulley 50 will cause the sprocket 43 to drive the chain 42 in advancing the upper and lower frame members 36 and 37 along the vertical tracks 40. The sleeve guide 20 is slidable independently of the main frame 35 but has its upper end affixed to the lower frame 37 so as to follow movement of the frame members 36 and 37 and impart corresponding vertical motion to the nozzle assembly. In addition, the motor M is affixed to a vertical motor mount 52 and together with the supply line 24 and tubing 21 will follow the vertical reciprocation of the sleeve guide. Preferably the track-engaging wheels are driven off a separate motor drive M" so that the rate of advancement of the guide assembly is closely coordinated with the rate of reciprocation of the sleeve guide while permitting the nozzle assembly to be oscillated independently under the control of the motor drive M. For the purpose of illustration, the motor drive M may consist of a one-half horsepower variable speed DC motor which is capable of oscillating the nozzle assembly at the rate of 750 cycles per minute; and for a suspension system consisting of the sleeve guide 20 and supports 20-22 being of an overall length on the order of 10 to 12 feet will cause displacement of the nozzle assembly approximately 1/2 inch in either direction. The angularly disposed nozzles or jets in turn will be capable of describing a generally serrated or zig-zag pattern as the assembly is simultaneously advancing along a vertical line of cut, again as illustrated at P in FIG. 2. In order to initiate a cutting operation, a hole is drilled to the desired depth, for instance, by a jack hammer, the hole being of a diameter to permit full insertion of the nozzle assembly to the bottom of the hole and with sufficient clearance for lateral oscillation. Drive motor M' is activated along with the oscillating motor M so that the nozzle assembly is oscillated as it is drawn upwardly through the hole to initiate cutting into the vertical wall represented at V. The depth or extent of cutting represented at V' is achieved by the delivery of water under pressure through the supply tube 17 into the nozzles 18 and in a pattern hereinafter described in more detail with reference to FIGS. 8 to 8B. At its upper end of travel at the top of the hole, upper frame 36 will depress a limit switch 53 causing motor M' to be de-energized and motor M" to be energized through a control circuit represented at 55. Preferably, the control circuit is designed to energize the motor M" for a time interval to advance the apparatus horizontally along the track a limited distance and in a direction corresponding to the depth of the cut. The motor M" is then de-energized and a reversing signal applied to the motor M' to drive the sleeve guide 20 downwardly through the hole in performing the next cut. Upon reaching the lower end of travel a limit switch 53' is engaged by lower frame 37 to de-energize the motor M' and energize the motor M" whereupon the entire sequence as described is repeated. Oscillation of the nozzle assembly 12 in a manner to be hereinafter described and shown in more detail in FIGS. 3 to 7 is operative not only to widen the channel but to finely pulverize the rock material so as to minimize spalling and impedance with the high pressure jets, in addition to other advantages referred to hereinafter. The rate of vertical advancement may be on the order of 10 feet per minute then is advanced horizontally a distance corresponding to the depth of cut 1/4 inch at the end of each vertical stroke. An alternate form of nozzle assembly 12' is illustrated in FIGS. 3 to 7 similar to that shown in the preferred embodiment wherein like parts with respect to those parts shown in FIGS. 1 and 2 are correspondingly enumerated, the nozzle assembly 12' being adapted specifically for the purpose of carrying out the horizontal cutting operations. The alternate form is seen to consist of a generally rectangular nozzle block 60 which is provided with a substantially horizontally extending manifold 61 formed internally of the block 60, and a series of exit ports or bores 62 extend downwardly from the manifold and are provided with enlarged counterbores at their lower ends for insertion of sapphire nozzles 63 supported in sleeves 63' threaded into the bores 62, as shown in FIG. 7. Preferably, the nozzles 63 are inserted at the upper ends of the sleeves 63' to define a conical orifice of a limited diameter on the order of 0.010 inches where for example the water is supplied at a pressure of 45,000 psi. A vertical bore or groove 64 serves as a supply conduit into the manifold 61 from an enlarged supply pipe or tube 65. Again tube 65 is secured by a retainer nut or union 66 in a recessed portion 67 of the block directly beneath an overhang 68 of the block, the tube extending upwardly into a pipe 65' which passes through the overhanging portion 68 for extension into the lower end of a sleeve guide, not shown, which corresponds to the sleeve guide 20 of FIGS. 1 and 2. A support rod 22 is provided with a lower threaded end 69 which is threadedly connected into a threaded bore in the upper end of the block in horizontally spaced relation to the supply tube 65'. In addition, a drive shaft 23 is journaled in a bearing 70 and terminates in a cam 72 which has an offset or eccentric 71 movable in an open channel formed between laterally spaced upwardly projecting plates 73. As shown in FIGS. 5 and 6, the eccentric reduced portion 71 is sized to be of a diameter corresponding to the spacing between the inner confronting surfaces of the plate 73 and is disposed in off-center relation to the enlarged end of the cam 72 whereby rotation of the drive shaft will impart lateral oscillation to the nozzle block 60 by causing the eccentric 71 to follow the path of rotation as illustrated at 72'. Although not shown, a suitable bearing may be formed on the eccentric 71 in order to minimize frictional engagement between the eccentric and the plates 73. The lateral oscillation which is imparted by th eccentric is communicated to the nozzle block 60 whereby to cause the nozzles to describe a cutting pattern as represented at P' in FIG. 4. Preferably, the nozzles are arranged so as to be angled in downwardly convergent relation to one another when viewed from the side, as in FIG. 3, to direct the individual jets represented at J along a common line; however, as viewed in FIG. 4 as well as FIG. 7, the jets or nozzles 63 are arranged along a diagonal line with the center jet striking the midpoint of the channel as represented at J' and the outer jets striking the outside corners of the channel as represented at J" so that when viewed from the front, or on a line parallel to the path of travel, the jet pattern is outwardly divergent across the width of the channel while cutting along a single line L in a direction normal to the length of the channel. Lateral oscillation will cause the jet streams to overlap one another as illustrated in FIG. 7A as cutting progresses in a horizontal direction by advancement of the main frame along the guide track, as described with respect to FIGS. 1 and 2. At the end of each cut or line of cut, the apparatus is reversed and the nozzle block lowered preferably a distance corresponding to the depth of cut in preparation for the next path along the channel to be formed as described in my hereinbefore referred to application for patent Ser. No. 610,577. Cutting may progress vertically for a distance limited by the length of the suspension means for the nozzle block and the vertical drive. Modified Form of the Preferred Embodiment A modified form of the present invention is illustrated in FIGS. 8, 8A and 8B in which a jet fluid cutting system is oscillated by alternating water jet pulses applied to the nozzle assembly through a separate water circulating system. Again, like elements to that form of invention shown in FIGS. 1 and 2 are correspondingly enumerated. In the modified form, nozzle assembly 12 includes a nozzle block 15, a manifold 16 which receives water under pressure through supply tube 17 for delivery into a series of nozzles 18 which are arranged to form the same jet impingement pattern as described with reference to FIGS. 1 and 2. In addition, a sleeve guide 20 permits vertical extension of the water supply tube 17 and also includes a support rod 22 which together with the support tube 17 serves to suspend the nozzle assembly 12 in spaced relation below the sleeve guide. Oscillation of the nozzle assembly is achieved in the modified form by alternating pulses of water under high pressure which are delivered to high pressure pipes 80 and 81, each pipe terminating at its lower end in a downwardly inclined, inwardly directed orifice 78 which is aligned to direct the water under high intensity into the upper side surface of the nozzle block 15. As best seen from FIGS. 8A and 8B, the orifices 78 and 78' are arranged for disposition on opposite sides of the nozzle assembly and are coordinated with a high intensity water source generally designated at 79 to alternately, or sequentially, deliver pulses of water against the side of the nozzle block at a frequency of rate such as to cause the nozzle block to oscillate in a direction transversely of the advancement of the entire assembly. The high pressure delivery conduits or pipes 80 and 81 extend intermediately of the water tube 17 and rod 22 through a lower extension 20' of the sleeve guide 20 from delivery hoses 82 and 83 leading from a piston pump 84 which is coupled to a motor drive 85, the pump 84 communicating with a suitable reservoir or supply source for the water as designated at 86. The pump 84 and motor drive 85 may assume other forms but broadly are designed to alternately deliver water to each hose 82 and 83 under sufficiently high pressure to be directed by the orifice 78 or 78' at an extremely high intensity and velocity against the side of the nozzle assembly. The system 79 is mounted on a main frame 88 which is provided with track-engaging wheels 89 adapted for advancement along a generally V-shaped guide track 90. A reciprocating frame 91 is adapted to suspend the sleeve guide along with the delivery conduits into the nozzle assembly and the nozzle assembly itself for vertical movement, the frame having rollers 92 which are arranged for rolling movement along opposite vertical sides of a vertical support frame or post 93, and the end of the frame 91 opposite to that supporting the sleeve guide is affixed to a chain drive which is defined by a chain 94 trained over upper and lower sprockets 96 and 97, respectively. The upper sprocket 96 is rotatably mounted on a support bracket 98 extending horizontally from the upper end of the post 93 and the lower sprocket is rotatably mounted on a bracket 100 projecting upwardly from the main frame 88. A variable speed drive motor 102 is drivingly connected to the chain drive through a suitable power transmission drive illustrated at 104 into the upper sprocket 96 so as to impart vertical movement to the nozzle assembly 12 along the desired line of cut. An upper limit switch 105 and a lower limit switch 106 are positioned on the vertical support 93 to define the upper and lower limit of the movement of the nozzle assembly, each of the limit switches being electrically connected to a suitable control circuit, not shown, into the horizontal drive motor 86 so that at the end of each vertical pass of the nozzle assembly, the vertical drive motor 102 will be de-energized and the horizontal drive motor 86 energized to advance the frame a limited horizontal distance for the next pass or line of cut in the same manner as described with reference to FIGS. 1 and 2. Initially a jack hammer hole is drilled into the quarry floor to a depth corresponding to the desired depth of the line or cut, the hole size being of a diameter to accommodate the nozzle assembly and sleeve guide with sufficient clearance for oscillation. In carrying out a typical cutting operation with the modified form of apparatus shown in FIGS. 8 and 8B, the tracks will be positioned to traverse the desired channel to be formed in the granite or other rock material with the nozzle assembly initially positioned in confronting relation to the vertical wall represented at V of the rock material designated R. Initially, the nozzle assembly may be set either at the bottom or top of the vertical line to be cut and the chain drive motor 102 initially activated by vertical movement of the nozzle assembly along the desired line of cut. As the nozzle assembly 12 is advanced along the vertical sidewall V, horizontal oscillation is simultaneously imparted to the nozzle assembly by energization of the oscillating drive motor 85 to cause alternating pulses to be discharged from the orifices 78 and 78'. By employing a motor drive and piston pump of the type described, pulses may be alternately delivered to opposite sides of the nozzle assembly to establish horizontal oscillation of the nozzle assembly which for example may be displaced on the order of 3/16 of an inch. As the nozzle assembly is oscillated, it is continuously advanced in a vertical direction until the sleeve guide 91 strikes the upper limit switch 105 to deactivate the drive motor 102 and activate the horizontal drive motor 86 to advance the entire apparatus along the track for an incremental distance in preparation for the next cut in the opposite direction. For the purpose of illustration, the incremental distance of movement may be on the order of 1/4 inch, at the end of which the control circuit will deenergize the horizontal drive motor 86 and reverse the vertical drive motor 102 to cause downward vertical movement of the nozzle assembly until the frame 91 reaches its lower limit of movement striking the lower limit switch 106 and once again de-energizing the vertical drive motor 102 and energizing the horizontal drive motor 86. Thus for each vertical pass or line of cut of the nozzle assembly approximately 1/4 inch of rock granite is eroded; and with the nozzle vibrating side to side at the rate of 750 cycles per minute will form a channel 3/4 inch wide along the vertical line of cut. By virtue of the divergent impingement pattern of the jets, the width of the channel will be greater than the width of the sleeve guide or nozzle assembly so as to assure more than enough clearance for horizontal oscillation and advancement of the nozzle assembly along the channel formed. It has been established through laboratory testing that even a single jet of high pressure fluid on the order of 45,000 psi is capable of cutting a slit in granite on the order of 3/16 inch deep and 1 inch long in one second, the slit being 0.010 inch wide. However, the same jet is capable of forming a groove 1/4 inch deep by 1 inch long in one second, and the groove will be 3/16 inch wide if the jet is oscillated sideways to move forward. Accordingly, substantially deeper penetration is obtained over a wider area if the jet is oscillated since the jet is not impeded by cavitation or bounce-back of water and material cuttings in the confines of the slit. In other words the channel is eighteen times wider and 1/16 inch deeper when even limited oscillation is employed since the oscillating jet is continually angling and cutting into the step formed in the sidewall for instance as represented at S in FIG. 8. This technique erodes a clear and open bottom for the escape of water and eroded material with little or no jet impedance. In cutting a channel in granite eight feet deep it is necessary to have the channel wide enough for the nozzles to follow movement along the channel, thus such channel width may be obtained with a series of jets, there being a series of three jets as illustrated in FIGS. 8 to 8B which are caused to form the divergent impingement pattern as illustrated. Preferably the nozzle is 3/8 inch wide and the oscillation stroke is 3/16 inch or a total of 9/16 inch in operation. The divergent or flared jets coupled with the oscillatory movement would therefore erode a channel 3/4 inch wide. The outside jets may be 0.011 inch orifice size. the inside jet an 0.009 orifice diameter. The stronger outside jets are needed for good penetration and cutting in the corners thereby assuring a straight wall in the channel and preventing the channel from narrowing. The traverse speed and oscillation speed will vary with the hardness and composition of the stone and for this reason it is preferable that variable speed motors be employed to control both functions. A medium hard granite may be cut with a traverse speed of 2 inches per second and an oscillation rate of 750 cycles per minute. The channel cutting rate is approximately 30 square feet an hour or three times faster than any present method employed. The cutting rate in limestone or other softer materials is two to three times faster which would permit much faster traverse speed and oscillation rate. In the quarry jet machine illustrated in FIGS. 8 to 8B, the nozzle is suspended for movement along a line of cut on the order of 8 feet. Thus the lance is lowered through the 8 foot distance following which the entire apparatus is advanced along the track for a limited distance on the order of 1/4 inch. The nozzle is reversed to advance along the desired line of cut in the opposite direction as earlier described following which the apparatus is horizontally advanced another limited increment until the entire channel is completed. Utilization of oscillating jets in the manner described has proven to pulverize the granite into a fine sand which will not tend to block or interfere with the nozzle movement, and further, oscillation by means of water jet pulses will increase the efficiency not only by its cooling action but in flushing out the fines as well. In the absence of oscillation, slitting and spalling can be expected to occur, the resultant chips being large enough to impede or interfere with the movement of the nozzle along the channel. As stated earlier, which the pattern of the jets diverges or flares in the lateral direction they also converge in the direction of the line of cut so as to form a straight line perpendicular to the channel. Accordingly, this straight line of impingement concentrates all the forces of the jets into a narrow band that results in the cutting, fracturing, granulating and eros ion of the crystals. Wider channels may be formed by increasing the stand-off distance between the nozzle and the material. Thus, while the normal distance from the nozzle to the surface may be on the order of 1 inch which will erode a channel 11/16 inch wide, a 2 inch spacing would permit erosion of a channel on the order of 1 inch wide. It has been found that the nozzle unit as described can be very effective for distances up to 21/2 inches from the cutting surface. Moreover, while the apparatus has been shown and described with respect to vertical channeling it is readily conformable for use in horizontal channeling or in other angles by modifying the frame to permit its adjustment to different attitudes. Of course in horizontal channeling most desirably the horizontal drive motor would be employed in advancing the nozzle assembly along the desired line of cut and the vertical drive employed for incrementally advancing the nozzle assembly in preparation for the next path or line of cut. From the foregoing, it will be recognized that the apparatus of the present invention permits formation of a channel that is smooth with straight sides and is sufficiently wide for the nozzle to operate in the channel and erode to a predetermined depth and of any desired length. In the preferred and modified forms disclosed in FIGS. 1, 2 and 8 to 8B the fan pattern is such as to assure the necessary width of channel and nozzle clearance in a direction transversely of the length of the channel; and by aligning the jets in a straight line along a direction perpendicular to the channel they are capable of concentrating and slotting in a relatively straight line across the channel to afford vastly improved cutting and pulverizing of the rock and minimizing spalling. Although the present invention has been described with a certain degree of particularly, it is understood that the present disclosure has been made by way of example and that changes in details and structure may be made without departing from the spirit and scope as defined by the appended claims.
A method and apparatus for cutting rock materials has been devised in which a series of jets are produced by a nozzle assembly, the nozzle assembly being constructed and arranged to advance along the surface of the rock material and to form a channel or line of cut of predetermined width and depth therein. As the nozzle assembly makes each pass along the intended line of cut, the assembly is oscillated in a direction transversely of its path of travel along the intended line of cut in order to better erode the material, form a clearly defined channel with a minimum of interference which may otherwise result from spalling or collection of liquid in the channel. Alternate forms of systems are disclosed which are capable of cutting at different selected angles ranging between vertical and horizontal lines of cut; and alternating forms of oscillating means are disclosed which may consist either of utilization of a revolving cam within a channel formed in the nozzle assembly or high intensity pulse jets which alternately deliver pulses of water under high intensity against opposite sides of the nozzle assembly.
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